Assembling PCBs is big business or fMot acSerr cei s vi r · SUPER AIR NOZZLES™ EXAIR’s Super...

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Skills Ontario wants to fill the gapBudget 2019: What’s in it for you?Manage extreme weather transport risksThree AI predictions for manufacturing

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Assembling PCBs is big business for Microart Services

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EVERY HEALTH & SAFETY JOURNEY STARTS WITH A STORY...

April 30–May 1, 2019 The International Centre | Mississauga ON

SCOTT STRATTEN How to Talk to the Younger Generation

MARK HENICK Mental Health Strategist

PartnersinPreventionConference.com

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www.plant.ca PLANT 3

EVERY HEALTH & SAFETY JOURNEY STARTS WITH A STORY...

April 30–May 1, 2019 The International Centre | Mississauga ON

SCOTT STRATTEN How to Talk to the Younger Generation

MARK HENICK Mental Health Strategist

PartnersinPreventionConference.com

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CONTENTS

PLANT—established 1941, is published 8 times per year by Annex Business Media. Publications Mail Agreement #40065710. Circulation email: [email protected] Tel: 416-442-5600, ext 3552 Fax: 416-510-6875 or 416-442-2191 Mail: 111 Gordon Baker Road, Suite 400, Toronto, ON M2H 3R1. Occasionally, PLANT will mail information on behalf of industry-related groups whose products and services we believe may be of interest to you. If you prefer not to receive this information, please contact our circulation department in any of the four ways listed above. Annex Privacy Officer: [email protected] Tel: 800-668-2374. No part of the editorial content of this publication may be reprinted without the publisher’s written permission. ©2018 Annex Publishing & Printing Inc. All rights reserved. Performance claims for products listed in this issue are made by contributing manufacturers and agencies. PLANT receives unsolicited materials including letters to the editor, press releases, promotional items and images from time to time. PLANT, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. This statement does not apply to materials/pitches submitted by freelance writers, photographers or illustrators in accordance with known industry practices. Printed in Canada. ISSN: 1929-6606 (Print), 1929-6614 (Online).

FEATURES

17 PERFORMANCE Make better decisions by liberating information from silos.

20 CCOHS SAFETY TIPS Protect employees from harassment and violence in the workplace.

21 SHOW TIME Partners in Prevention 2019 celebrates safety superheroes.

23 THINK LEAN How riding the white water parallels leadership in manufacturing.

25 INSIDE MAINTENANCE Protect electrical assets with a move to condition monitoring.

TECH TIPS VFDs: How to avoid typical grounding problems.

26 MAINTENANCE FRAMEWORK The document takes performance to a higher level.

April 2019Vol. 78, No. 03

12 ELECTRONICS Microart Services is assembling printed circuit boards in Canada and the business is growing, driven by connectivity.

18 FINANCE Budget 2019: What’s in it for manufacturers? Not a lot…

15 PRESSURE POINT Skills Ontario is advancing its agenda to increase engagement and build momentum.

24 CASE HISTORY How RCM helped a medical device manufacturer get more value from its assets.

19 LOGISTICS Ten tips for managing the impact of extreme weather on transportation.

COVER: RODNEY DAWS

DEPARTMENTS 4 Editorial 6 News Bulletins 7 Feedback Careers 8 PLANT Online 10 Industry Mix11 Economy PLANT Pulse 29 Tech Centre Feature:

Three AI predictions for 201931 Leading Edge:

Innovative ideas for plants32 Products and Equipment 33 Plantware Events 34 Postscript


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SUPER AIR NOZZLES™EXAIR’s Super Air Nozzles provide a high thrust, concentrated stream of high velocity airflow and are engineered to reduce noise levels and air costs. The sound level is as low as 58 dBA with hard-hitting force up to 23 pounds. All meet OSHA noise and pressure requirements.

https://exair.co/18_super_ad

MICRO AIR NOZZLE FOR PRECISION BLOWOFFThe Micro Air Nozzle is one of the smallest available. EXAIR’s “precision blowoff” provides optimum air entrainment for a directed high volume, high velocity airflow. The compact size permits mounting where space is limited.

https://exair.co/18_micro_ad

EFFICIENT AIR GUNS, COMFORTABLE GRIPSafety Air Guns use engineered Air Nozzles to provide superior performance. Safe operation is assured along with low air consumption and noise level. VariBlast Compact, Soft Grip, Heavy Duty and Super Blast Safety Air Guns are available. Extensions and Stay Set Hoses are available.

https://exair.co/18_sag_ad

NON-MARRING PEEK SUPER AIR NOZZLESPEEK (plastic) Super Air Nozzles feature non-marring and excellent chemical compatibility properties. These award winning nozzles come in a variety of sizes with force from 2.0 ounces to 1.9 pounds. PEEK nozzles can be used with temperatures up to 320°F (160°C).

https://exair.co/18_peek_ad

UNIQUE FLAT NOZZLES USE PATENTED TECHNOLOGYThe 2" Flat Super Air Nozzle™ is a highly efficient, unique flat air nozzle. Using EXAIR’s patented technology, a precise amount of air is released through the thin slot, across a flat surface. The result is a wide, forceful stream of high velocity, laminar airflow. 1" Flat Super Air Nozzle™ available as well!

https://exair.co/18_2san_ad

NOZZLE CLUSTER, HIGHEST BLOWING FORCEMany blowoff, cleaning, cooling and drying applications require high force and extensive reach. EXAIR’s Super Air Nozzle Clusters deliver up to 9.8 lbs of force. Three sizes for handheld and stationary mounting are available. Available on Super Blast Safety Air Guns for ease of use.

https://exair.co/18_blast_ad

BACK BLOW NOZZLES CLEAN INSIDE DIAMETERSEXAIR’s Back Blow Nozzles are engineered to clean inside of pipe, tube, hose or channels. An array of holes provide a forceful 360˚ airflow to clear out coolant, chips or debris created from machining processes. This nozzle prevents blowing chips further into a pipe or out the opposite end of the pipe.

https://exair.co/18_back_ad

BUILD YOUR OWN SYSTEMEXAIR’s Swivel Fittings, available for all our nozzles up to 1 NPT, make it easy to adjust the aim of the Air Nozzles and Jets. Correct placement of the blowing angle can helpoptimize performance, reduce noise levels and improve efficiency.

https://exair.co/18_swivel_ad

This small Super Air Nozzle costs only $41. Installing it in place of one 1/4" copper tube can save you $592.80 per year.

Here’s how:A 1/4" copper tube is a common homemade blowoff that consumes 33 SCFM when at a normal supply pressure of 80 PSIG. EXAIR’s award winning Model 1100 Super Air Nozzle is 1/4 NPT and consumes only 14 SCFM at 80 PSIG.

33 SCFM (copper tube) - 14 SCFM (Super Air Nozzle) = 19 SCFM compressed air saved. For this example, the blowoff is continuous.

Most large plants know their cost per 1,000 standard cubic feet of compressed air.If you don’t know your actual cost per 1,000 SCF, 25¢ is a reasonable average to use.

SCFM saved x 60 minutes x cost/1,000 SCF = Dollars saved per hour.In this case, 19 SCFM x 60 minutes x .25/1,000 = 28.5 cents per hour.28.5 cents per hour x 40 hour work week = $11.40 per week.$11.40 per week x 52 weeks = $592.80 per year.The Super Air Nozzle pays for itself in three weeks. For more information, visit https://exair.co/18_410 If you would like to discuss an application, contact an Application Engineer at:

1400% Return on Investment!

11510 Goldcoast Drive, Cincinnati, Oh 45249-1621 1 (800) 903-9247 fax: (513) 671-3363

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4 PLANT April 2019

EDITORIAL

Two bits of news coincided in an ironic juxtaposition on April Fools Day: the beginning of the Trudeau government’s carbon tax levied on Saskatchewan, Manitoba, Ontario and News Brunswick; and a troubling report that Cana-

da’s climate is warming twice as fast as the rest of the world and the warming is “effectively irreversible.”

The challenge for any government is to balance climate change action with its impact on the economic well being of the country. That brings us to the carbon pricing policy and whether or not it’s effective. The verdict? Likely not.

Economists favour carbon pricing for reducing global-warming emissions by charging those who emit carbon dioxide (CO2). They declare it to be the most efficient tactic, the outcome determined by the market rather than by regulation, and the favoured result is achieved by encouraging energy users to change their behaviour.

The Trudeau government’s tax starts at $20 per tonne of greenhouse gas emis-sions produced by energy use, rising to $50 by 2022. Good news for consumers though: it’s revenue neutral! They’ll get what the government suggests the tax will cost them back in tax credits. How that will encourage people to change their behaviour remains to be seen, but this deal is very different for businesses, and SMEs in the manufacturing sector should be alert.

Canadian Manufacturers & Exporters says the impact on Ontario could be sub-stantial, noting the country already has a problem attracting investment.

The carbon plan contributes to the difficulty by adding cost and regulatory entanglements that hinder businesses’ ability to compete globally, and these entanglements make foreign investment in Canada less attractive.

The Canadian Federation of Independent Business (CFIB) sees businesses carrying 50% of the carbon price burden but they’ll get just 7% of the rebates. And there are a lot of unanswered questions about how the process will work, who gets an exemption and what documents will be required. The CFIB also dismisses the assumption that SMEs already operating under very competitive conditions can just pass the costs off to consumers.

And carbon pricing window dressing alert: a secret federal government briefing document says the price would have to go up to $100 per tonne by 2020 and between $200 and $300 per tonne by 2050 to reach Canada’s greenhouse gas emis-sion commitment (30% below 2005 levels by 2030). The United Nations suggests Canada needs to cut emissions even more to prevent the worst climate-change impacts. Canada has already missed two emissions reduction targets and is on its way to being off its 2020 target by 20%, never mind the 2030 Paris Accord commit-ment.

The report from Environment and Climate Change Canada says the average temperature is 1.7 degrees C higher today than it was 70 years ago, versus an increase in the average global temperature of 0.8 degrees C.

Meanwhile, global emissions continue to climb. If the world keeps emitting at the same rate, by 2050 most parts of Canada will see increases of between 7 and 9 degrees C, with the extreme Arctic heating up by more than 11 degrees C. So far, Canada is responsible for 1.69% of CO2 emissions. More than half the world’s emissions come from China (26.83%), the US (14.36%) and the EU 28 (9.66%).

Government policy under the Harper and Trudeau regimes has been more political expediency than effective strategy. Future Canadian governments must acknowledge the top emitters will determine the impacts of climate change on Canada’s environment. The issue must be approached more realistically based on what we can and can’t control, balanced against Canada’s economic health and with the hard decisions that may follow.

Joe Terrett, Editor Comments? E-mail [email protected].

Carbon pricingoffers cold comfort

Vice President/Executive PublisherTim Dimopoulos(416) 510-5100 [email protected]

EditorJoe Terrett416-442-5600 ext. [email protected]

Media DesignerAndrea M. [email protected]

National Account Manager Ilana Fawcett416-510-5202 [email protected]

Account Coordinator Debbie Smith416-442-5600 ext [email protected]

COOScott [email protected]

President & CEOMike Fredericks

Circulation ManagerBeata Olechnowicz416-442-5600 ext. [email protected]

Subscription PriceCanada $76.00 per year, US $154.50 (US) per year, Foregin $174.50 (US) per year. Single Copy Canada $12.00. Add applicable taxes to all rates. Combined, expanded or premium issues, which count as two subscription issues.

Mailing AddressAnnex Business Media 111 Gordon Baker Road, Suite 400Toronto, ON M2H 3R1

CirculationBona Lao 416-442-5600 ext. 3552 [email protected]: 416-510-6875 or 416-442-2191











SUPER AIR NOZZLES™EXAIR’s Super Air Nozzles provide a high thrust, concentrated stream of high velocity airflow and are engineered to reduce noise levels and air costs. The sound level is as low as 58 dBA with hard-hitting force up to 23 pounds. All meet OSHA noise and pressure requirements.


MICRO AIR NOZZLE FOR PRECISION BLOWOFFThe Micro Air Nozzle is one of the smallest available. EXAIR’s “precision blowoff” provides optimum air entrainment for a directed high volume, high velocity airflow. The compact size permits mounting where space is limited.


EFFICIENT AIR GUNS, COMFORTABLE GRIPSafety Air Guns use engineered Air Nozzles to provide superior performance. Safe operation is assured along with low air consumption and noise level. VariBlast Compact, Soft Grip, Heavy Duty and Super Blast Safety Air Guns are available. Extensions and Stay Set Hoses are available.


NON-MARRING PEEK SUPER AIR NOZZLESPEEK (plastic) Super Air Nozzles feature non-marring and excellent chemical compatibility properties. These award winning nozzles come in a variety of sizes with force from 2.0 ounces to 1.9 pounds. PEEK nozzles can be used with temperatures up to 320°F (160°C).


UNIQUE FLAT NOZZLES USE PATENTED TECHNOLOGYThe 2" Flat Super Air Nozzle™ is a highly efficient, unique flat air nozzle. Using EXAIR’s patented technology, a precise amount of air is released through the thin slot, across a flat surface. The result is a wide, forceful stream of high velocity, laminar airflow. 1" Flat Super Air Nozzle™ available as well!


NOZZLE CLUSTER, HIGHEST BLOWING FORCEMany blowoff, cleaning, cooling and drying applications require high force and extensive reach. EXAIR’s Super Air Nozzle Clusters deliver up to 9.8 lbs of force. Three sizes for handheld and stationary mounting are available. Available on Super Blast Safety Air Guns for ease of use.


BACK BLOW NOZZLES CLEAN INSIDE DIAMETERSEXAIR’s Back Blow Nozzles are engineered to clean inside of pipe, tube, hose or channels. An array of holes provide a forceful 360˚ airflow to clear out coolant, chips or debris created from machining processes. This nozzle prevents blowing chips further into a pipe or out the opposite end of the pipe.


BUILD YOUR OWN SYSTEMEXAIR’s Swivel Fittings, available for all our nozzles up to 1 NPT, make it easy to adjust the aim of the Air Nozzles and Jets. Correct placement of the blowing angle can helpoptimize performance, reduce noise levels and improve efficiency.


This small Super Air Nozzle costs only $41. Installing it in place of one 1/4" copper tube can save you $592.80 per year.

Here’s how:A 1/4" copper tube is a common homemade blowoff that consumes 33 SCFM when at a normal supply pressure of 80 PSIG. EXAIR’s award winning Model 1100 Super Air Nozzle is 1/4 NPT and consumes only 14 SCFM at 80 PSIG.

33 SCFM (copper tube) - 14 SCFM (Super Air Nozzle) = 19 SCFM compressed air saved. For this example, the blowoff is continuous.

Most large plants know their cost per 1,000 standard cubic feet of compressed air.If you don’t know your actual cost per 1,000 SCF, 25¢ is a reasonable average to use.

SCFM saved x 60 minutes x cost/1,000 SCF = Dollars saved per hour.In this case, 19 SCFM x 60 minutes x .25/1,000 = 28.5 cents per hour.28.5 cents per hour x 40 hour work week = $11.40 per week.$11.40 per week x 52 weeks = $592.80 per year.The Super Air Nozzle pays for itself in three weeks. For more information, visit https://exair.co/18_410 If you would like to discuss an application, contact an Application Engineer at:

1400% Return on Investment!

11510 Goldcoast Drive, Cincinnati, Oh 45249-1621 1 (800) 903-9247 fax: (513) 671-3363

EXAIR_ROI_AirNozzleJet.indd 1 3/22/19 2:06 PM

PLT_April19_Exair.indd 1 2019-03-25 9:41 AMPLT_April 2019_AMS.indd 5 2019-04-04 2:57 PM









https://exair.co/18_410

6 PLANT April 2019

NEWS

BULLETINS

Magellan Aerospace Corp. has landed a five-year deal valued at $48 million with the Canadian government to perform the licensed manufacture of LUU-2 illu-mination flares for the Royal Canadian Air Force. The flares will be delivered from the Winnipeg facility’s propellant plant in Manitoba. The air-deployed flares support night search and rescue operations, producing about 1.8 million candlepower of visual illumination for five minutes. Magellan is a global aero-space company that provides complex assemblies and systems to aircraft and engine manufacturers, and defence and space agencies.

An unnamed Houston-based pipeline operator has adopted OneBridge Solutions Inc.’s cognitive integrity man-agement (CIM) software-as-a-service solution for long-term use for its US and Canadian operations. The client owns crude oil, natural gas liquid and natural gas midstream assets. OneBridge is an Edmonton-based subsidiary of OneSoft Solutions Inc. in the US, which has developed machine learning and data science software that transitions legacy software applications to operate on the Microsoft Azure Cloud Platform.

Magna International has completed the $1.23 billion sale of its Fluid Pressure & Controls (FP&C) business to Hanon Systems, a South Korea-based global supplier of thermal and energy manage-ment systems. The sale was announced in September 2018. The global FP&C business specializes in mechanical and electronic pumps, electronic cooling fans and other components. Approx-imately 4,200 employees across 10 facilities in North America, Europe and Asia will transition to Hanon Systems.

Veritiv Canada Inc. in Mississauga, Ont. will be the exclusive Canadian distributor of coated sheets from Asia Pulp & Paper, a group of pulp and paper manufacturers in Indonesia and China. This type of paper is used by commercial printers for catalogues, magazines, high-end advertising materials, annual reports, as well as other media and marketing applications. Veritiv Corp. in Atlanta is a provider of print and paper solutions.

Campbell’s Soup plant assets for saleToronto plant’s equipment valued at $200 million

TORONTO — A joint venture group has ac-quired the machinery and other assets of the Campbell’s Soup factory in Toronto and will be selling them privately until the end of summer. At that point, a public auction will follow for the remainder of the assets.

TCL Asset Group Inc., Corporate Assets Inc., Rabin Worldwide and Capital Recovery Group LLC value the assets at more than $200 million (replacement cost).

They include canning and aseptic filling and packag-ing lines capable of handling more than 20 million cases of soup; a vegetable receiving department; multi-batch pump area; processing department; elmar canning lines; combibloc aseptic filling and packaging lines; aseptic pilot plant; labelling and case packing department; power and facility equipment; co-generation system; and general plant equipment.

The Campbell Soup Co. of Canada announced the clo-sure of the 600,000 square-foot Etobicoke plant in January, putting 380 workers out of work. The plant shuts its doors in May. The company said the plant, which opened in 1931, was its oldest and smallest, and not suitable for retrofit. But Campbell’s is also dealing with overcapacity and fall-ing soup sales so production at the Toronto plant has been shifted to the US.

PEMAC’s AMP program moving to an Alberta collegeMISSISSAUGA, Ont. — The Asset Man-agement Professional (AMP) education and certificate program from the Plant Engineering and Maintenance Associa-tion of Canada (PEMAC) is moving to a new home.

The program is transitioning, course by course, from Humber College in To-ronto to Northern Lakes College in Slave Lake, Alta.

AMP introduces participants to the latest in strategic asset management thinking from recognized global organi-zations. Participants build knowledge and skills in risk management and knowledge management (enterprise database systems); and are introduced to tools that will be applied to strategic decision-making at each stage of the asset lifecycle.

Six courses are delivered online, each led by experienced instructors.

The transition schedule allows profes-sionals who have started the program with Humber College to complete it there, while new candidates will work with Northern Lakes College. Successful completion of the six courses leads to the CAMP professional designation.

Arctic surf clam fishery reconciledClearwater Seafoods and 14 First Nations forge 50-year partnershipHALIFAX — Clearwater Seafoods Inc. and 14 First Nations communities in Nova Scotia and Newfoundland-Labrador have forged a 50-year partnership. It protects existing jobs in the Arctic surf clam fishery while creating economic ben-efits, employment and capacity building for the First Nations adjacent to the resource.

The agreement provides millions of dollars in benefits to First Nations through annual revenue sharing, training, leadership development and employment, plus procurement of goods and services from Indigenous suppliers.

This agreement also protects the workers at the Grand Bank Seafoods plant.

“This is a business development model that has been successful for our community in other sectors and it makes sense to extend it to the seafood industry with Clearwater, as they have industry knowledge and experience,” said Chief Terrance Paul, Chief of Membertou First Nation and co-chair of the Assembly of Nova Scotia

Mi’kmaq Chiefs. Clearwater, based in Bedford, NS, is one of

North America’s largest vertically integrated seafood companies and the largest holder of shellfish licences and quotas in Canada.

Modern soup-making equipment. PHOTO: JOINT VENTURE

Chief Terrance Paul, co-chair of the Assembly of Nova Scotia Mi’kmaq Chiefs, and Clearwater CEO Ian Smith onboard the clam vessel Anne Risley. PHOTO: CLEARWATER



CAREERS

Bombardier has appointed Steeve Robitaille senior vice-president, general counsel and corporate secretary. Robitaille succeeds Daniel Desjardins who will continue to serve as a special advisor to Alain Bellemare, president and CEO of the Montreal-based global transportation company. He has been serving as chief legal officer, executive vice-president, merger and acquisitions for WSP since 2017.

Boralex Inc., an operator of renew-able energy projects based in Montreal, has appointed Patrick Decostre as vice-president and COO. Nicolas Wolff will replace him as vice-president and general manager of Boralex Europe. Previously, he was vice-president and general manager of Vestas Western Mediterranean, a wind energy compa-ny based in Denmark.

Algoma Steel Inc. has appointed Mi-chael McQuade CEO. Prior to becoming a director of the Sault Ste. Marie, Ont. steelmaker in 2018, he held a number of executive positions at Stelco Inc., including president in 2014. He succeeds Kalyan Ghosh who served as CEO prior to and during the successful restructur-ing of Algoma’s business in 2018. Ghosh resigned from the company to pursue other opportunities.

Martin Brassard is the new president and CEO of Heroux-Devtek. The global company based in Longueuil, Que. man-ufactures landing gear, actuation sys-tems and components for the aerospace market. Brassard joined the company in 1994 and has held several key roles since then. In 2014, he was promoted to vice-president and COO.

PyroGenesis unveils its NexGen systemDeclares production advances for AM powders

MONTREAL — PyroGenesis Canada Inc. has unveiled a new system that produces metal powder at faster than 25 kilograms per hour for the additive manufacturing (AM) industry.

The Montreal company that manu-factures and commercializes plas-ma atomized metal powder said its NexGen Plasma Atomization System targets higher production rates and narrower particle size distribution. This allows the production of a very targeted powder for the AM industry, with little to no waste.

Big corps more engaged with green energy activities MISSISSAUGA, Ont. — Most large companies around the world are engaged in energy conservation and climate action activities, according to a Schneider Electric study.

The 2019 Corporate Energy & Sustainability Progress Report looks at the global trends, barriers and opportuni-ties impacting enterprise energy and carbon-management programs.

Here are some highlights from the survey of more than 300 global professionals responsible for energy and sus-tainability at businesses with more than $100 million in annual revenue:• Nearly 60% have goals they’ve shared with customers,

investors and other stakeholders. • 28% are specific and ambitious in their goals, joining

established initiatives such as RE100, science-based targets and zero waste to landfill.

• Companies operating in multiple geographies are nearly 10% more likely to make a public commitment than those in one region.

• Europe-based businesses set public goals more often than their North American peers (65% versus 58%).

• Most publicly committed companies (59%) see environ-mental concerns as the primary driver, above financial considerations (52%).

• These companies are more likely to implement advanced technology such as on- and offsite renewables, battery storage and electric vehicles.Schneider Electric is a suppplier of energy management

and automation technology based in Mississauga, Ont.

Process produces little or no waste. PHOTO: PYROGENESIS

Steeve Robitaille

Patrick Decostre

Nicholas Wolff

FEEDBACK

Rountable disappointment: No women

I just received my copy of the PLANT Manufacturers’ Outlook 2019. There are many business issues affecting Canadian manufacturers and you have provided a concise and accurate picture for your readers to understand and it provides a great base for further discussion within our company.

My only disappointment was the roundtable panel did not include any women representatives.

There are many women in-volved and leading Canadian

manufacturing companies. As corporate boards look to be more inclusive with more women as members, I would like to see this roundtable also push for a 50/50 repre-sentation in the future.Doris Valade, CEOMalabar Super Spice Co. LtdBurlington, Ont.

We’d like to hear from you. Send comments to [email protected] with your name, address and phone number. Comments will be edited.

$100M for SMEs impacted by steel and aluminum tariffsOTTAWA — The Liberal government in Ottawa is offering steel and alumi-num SMEs and users impacted by US tariffs on the metals $100 million in funding.

The Trump Administration in Wash-ington imposed tariffs of 25% on steel and 10% on aluminum imports from Canada and other countries claim-ing they were a threat to national security.

The initiative will provide 300 man-ufacturers and users across Canada with non-repayable contributions for projects that enhance productivity and apply advanced technologies that will help them scale up and find new markets.

In 2017, Canada’s steel and alumi-num industry employed more than 33,500 people and contributed $8.9 billion to the country’s gross domes-tic product.



8 PLANT April 2019

NEWS

SOUNDING OFFWhat readers have to say about breaking news

PLANT ONLINEHave you checked out PLANT’s daily news online? Here are some headlines that have inspired members of the Canadian manufacturing community to chime in. They’re edited, but use the links to see the raw – and for some – longer versions of their remarks plus the stories that inspired their reactions.

Stay up-to-date on the developments – domestic and global – that affect Canada’s industrial sectors by watching the news feed at www.plant.ca or reading PLANT’s twice-weekly newsletter (hit Subscribe on the website).

UK government defiant as Parliament takes control of Brexit http://www.plant.ca/gtMBT

May is beating a dead horse. She wants it to be her legacy and is willing to do anything to get it. Britain would be better off to cancel Brexit for the time being, then put a package together to promote to the [EU] well in advance of actually doing anything.

USMCA getting a boost from Trump, business grouphttp://www.plant.ca/3mGvV

The tariffs on steel and alu-minum for Canada and Mexico have to go. Canada has given up enough.

Wind turbine catches fire at Nova Scotia wind farmhttp://www.plant.ca/b0EhK

Why don’t wind turbines have automatic fire-extinguisher sys-tems (halon?). Can’t be that hard or expensive to do.

Why is there no requirement for automatic internal fire suppression and for a fail-safe mechanism that locks or at least brakes the nacelle main shaft if fire is detected? Why is the blade coating flammable?

BC not trying to stop Trans Mountain, aims to protect environment: lawyerhttp://www.plant.ca/PowwN

So it’s all about the environ-

ment and killer whales. Then explain how Vancouver and Victoria are able to dump their raw sewage untreated into the very waters they profess to pro-tect for killer whales. How does the BC government square the expansion of ferry operations or expanded traffic for natural gas or even the intrusive whale watching industry? Doesn’t the same argument stand against their projects of profit? Selective environmental stewardship on interprovincial projects doesn’t hold water. The fact remains the NDP government campaigned on stopping this pipeline at all costs. Obtaining a legal opinion after the fact does not change the song you sang.

Trump raises possibility of walking away from China dealhttp://www.plant.ca/JEm5n

Really!! When did Trump ever learn the meaning of the word egregious?

Allegations Trudeau inter-fered in SNC-Lavalin case concern OECDhttp://www.plant.ca/CrRr9

Trudeau’s replies for the last several months to all questions have been evasions and pre-writ-ten by office staff to mislead and misdirect any attempt at solving the problems facing the country.

MO tried to persuade Wil-son-Raybould, not intimidate her: Buttshttp://www.plant.ca/VHtb8

None of his “testimony” is valid since he refused to take an oath. This is the same guy that ruined Ontario with the “green” energy “windfall” to put Ontario in more debt (per capita) than Greece and California. “Liberals used their majority on the committee to reject an opposition proposal to recall Wilson-Raybould to respond to Butts’s comments.” This tells the whole story!

CellCube wins 100-MW US projectMoving into grid capacity applications for its energy storage systems

TORONTO — CellCube Energy Storage Systems Inc. has signed an agreement with a US-based energy asset development company to develop up to 100 megawatts (MW) of energy storage systems for deployment throughout the US.

Financial details and the name of the customer were not provided.

The Toronto-based supplier of en-ergy storage systems said the market enables offtake agreement resources for independent system and regional transmission operators through prod-uct and service deliveries into sched-uled projects. They’ll be deployed over the next 24 to 36 months.

The systems will be placed as standalone plants or co-located with solar to offer power market-traded energy supply and ancillary services.

CellCube develops, manufactures, and markets its energy storage systems

based on vanadium redox flow technology and has more than 136 project installations.

The company recently acquired the assets of Gildemeister Energy Storage, the German manu-facturer of CellCube energy storage systems.

Stelco signs on with Canvass for AITORONTO — Canvass Analytics Inc., a provider of artificial intelligence (AI) software for industry, has signed a deal with Stelco that will see the Hamilton steel maker use the platform.

Canvass Analytics leverages AI and machine learning to transform previ-ously unconnected data into predictive analytics.

The Toronto company’s technology bridges the gap between workforce knowledge and curated Internet of Things inputs to minimize energy con-sumption, increase throughout, reduce downtime and extend the lifetime of a plant’s assets.

BI Intelligence predicts global man-ufacturers will invest $70 billion in IoT solutions in 2020, up from $29 billion.

CellCube energy storage system. PHOTO: CELLCUBE

CANADA’S TOP SERVICE PROVIDERSIf you are one of Canada’s leading solutions providers, we invite you to be part of the 2019 Ontario Export Awards by showcasing your expertise to a diverse industrial executive audience of top companies in global growth mode

Contact Ilana to learn more about how participation in the 2019 Ontario Export Awards can position you as a leader of industry.

ILANA FAWCETT | National Account ManagerAnnex Business Media

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10 PLANT April 2019

EV subsidies don’t add upSince transportation accounts for about 25% of Canada’s greenhouse emissions, some jurisdictions have opted to ladle out dollar incentives to en-courage people to buy electric vehicles (EVs). Since 2012, Quebec has spent more than $220 million in subsidies to “encourage” purchases, says the Montreal Economic Institute, and the spending will continue. But the MEI notes this policy is very expensive, with very little impact on emissions. If Quebec achieved its dubious objective of having a million EVs on the road by 2030 – 20 times more than it has now – it would only reduce GHG emissions by 3.6%. Here’s some more math: So far the $8,600 subsidy cost taxpayers a little under $300 of GHGs not emitted. With the new $5,000 federal subsidy, the cost per tonne jumps to more than $450, or 23 times the carbon market price or the federal tax amount. Meanwhile, Canada isn’t even close to meeting its Paris Accord obligations (30% below 2005 levels by 2030). In fact, a report by Canada’s auditor gen-erals says the country is likely to miss the old 2020 Copenhagen target by nearly 20%.

Paris Accord commitment: 30% below 2005 levels by 2030. PHOTO: ADOBE STOCK

The federal government, Prime Minister Trudeau himself,

and all party leaders must be very clear with the Americans that this trade

agreement will not be ratified until tariffs and quotas are removed from the equation.

United Steelworkers Canadian director Ken Neumann and Quebec director Alain Croteau, referring to the US-Mexico-Canada

Agreement (USMCA) awaiting Canadian ratification.

MISCELLANY FROM THE WORLD OF MANUFACTURING

AI and killer robotsWith all the talk about Industry 4.0 and artificial intelligence, it was only a matter of time before the discussion got around to killer robots (aka Lethal Autonomous Weapons Systems). Yes, that’s a thing. Associate Press reported Japan’s ambassa-dor to the United Nations-backed Conference on Disarmament told experts his country has not developed fully autonomous weapons systems, and has no plans to do so. Phew! Nobushige Takamizawa noted some positives of autonomous weapons systems under human oversight, such as saving labour and reducing collateral damage. But killer robot opponents fear one day the machines could conduct wars without human control. Have we learned nothing from the Terminator movies and the global mischief Skynet instigated? Manufacturers, be leary of all this AI and IIoT stuff. Fertile conditions for the autonomous production of Terminators. Yikes!

Watch out for this guy. PHOTO: ADOBE STOCK

Get smooth on CBD beveragesCanada’s food and beverage sector is in for a bit of disruption. The burgeoning cannabis industry is moving into edibles (regulations will be in place Oct. 17). Companies will be adding drinks infused with cannabidiol (CBD) to the other concoctions that will be available for good health, as in therapeutic. CBD is non-psychoactive, so nobody is getting high on one of these tipples. But “users” are supposed to experience reduced anxiety, nausea relief, decreased muscle and joint pain, among other benefits. Let’s not leave out the pets. The cannabis producers are also expecting CBD-for-Fido to garner a large share of the market. Canadian company Tilray has acquired Manitoba Harvest, which gives it access to a broad portfolio of food products distributed across the US and Canada. And Molson Coors’s Canadian arm is working with Hydropothecary to produce cannabis-infused drinks. Time for a new Molson beer slogan: “Let’s get smooth.”

INDUSTRY MIX

Brewers crying in their sudsBrewers of Canadian beer aren’t too happy with Federal finance minister Bill Mor-neau’s 2019 budget. The “Investing in the Middle Class” plan appears to be doing so with help from the escalating booze tax put into effect in 2017. That’s the third increase in two years. Beer Canada, which advocates for

companies that make about 90% of domestically made suds, wanted to see and end to the tax on alcoholic beverages. It’s a sneaky tax that accounts for 47% of a pint, aimed at the brewers and built into production costs. Since it’s automatic each year, the increase isn’t debated in Parliament. Beer Canada says the annual hike bumps up GST/PST/HST and other taxes, doubling and tripling the tax hit to our wallets. How much is the hit? Hard to say. It’s also a complicated tax that varies depending on the product and percentage of alcohol. So cheers middle-class Canadians! When the price of your favourite cold one goes up each year, don’t blame the poor brewers.

Triple tax hot for beer drinkers. PHOTO: ADOBE STOCK

Cannabis-infused soft drinks. PHOTO: ADOBE STOCK



$54.45BILLION

Value of the global

industrial robotics market

by 2024. North America’s

automation market has

been doing a lot of buying.

In the first nine months

of 2017, 27,294 orders

valued at approximately

$1.97 billion, were

sold in North America.

ResearchAndMarkets.com

The annual amount of loss and waste representing 58% of the commodities entering the Canadian food system. Of that, 11.2 million tonnes or 32% is avoidable. Avoidable waste is equal to 94 CN towers, at a value of $49.5 billion (51.8% of the dollars consumers spend on food) and 56.5 million tonnes of CO2 equivalent. Although 4 million Canadians have insufficient

access to food, an estimated 86% of the avoidable waste that occurs along the value chain is not rescued and redistributed. Source: Value Chain International, The Avoidable Crisis of Food Waste – Technical Report

Job vacancies in

manufacturing (up 20.9%)

in Q4 of 2018. Over the

same period, the job

vacancy rate rose 0.4 percentage points to 3%,

coinciding with year-over-year payroll employment growth.

Statistics Canada

8,400

ECONOMY

An aging workforceBe nice to older workers

If manufacturers think there’s a prob-lem finding skilled people now, just wait. Longer term, Statistics Canada

is projecting the overall participation rate in the labour force will decrease, mainly because of the aging popula-tion. As time passes, those aged 55 and older will represent a growing proportion of employees.

The agency warns aging has important consequences for the Canadian economy. With more people leaving and fewer people entering the labour market, some sectors face the prospect of shortages. And a lower overall participation rate will likely put pressure on fiscal revenues, which fund essential social and economic services and programs.

Nationally, older workers could make up more than 25% of the labour force in 2036, compared with 21% in 2017 or 11% in 1976.

Meanwhile on a more immediate timeline, a 2017 labour analysis based on the next five and 10 years, reports manufacturers in nearly every one of the 15 regions studied will have to overcome a recruitment gap to sustain production and grow.

The Future of the Manufacturing Labour Force by Canadian Manufac-turers & Exporters, and the Canadian Skills Training and Employment Coalition notes demand for skilled workers will surpass supply in 14 of the regions over the next 10 years.

Manufacturers need to address the effects of its aging demographic. Old-er workers are staffing key occupa-tions and they’ll be leaving their jobs over the next 10 years.

The report warns replacing them will be the most important human resources issue for manufacturers. The top four hiring challenges will be machinists, millwrights and industri-al mechanics, welders and manufac-turing managers.

Statistics Canada says there are many factors driving the increase in working seniors, including better health and longer life expectancy; higher levels of education; and their financial security.

What does this mean for manufac-turers? Be nice to your older workers. You might need to convince them to stick around.

Goods for use as an intermediate input for domestic

production, the second largest expenditure for

Canadian enterprises. Manufacturers account

for 60%. Goods were mainly bought from other

Canadian businesses ($184 billion). Statistics Canada

Real gross domestic product

expanded 0.3% in January,

offsetting declines in November and

December. The rise was widespread

with 18 of 20 industrial sectors showing

increases. The output of goods-

producing industries increased 0.6%, led

by growth in manufacturing. It rose 1.5%,

more than offsetting declines during

the previous two months. Growth was

widespread across subsectors in both

non-durable and durable manufacturing.

Services rose 0.2% with all but one

sector increasing.

MANUFACTURING GDP RECOVERS

$279 BILLION

35.5MILLION TONNES

Average investment in

machinery, equipment

and technology for 2019 by all respondents to the

PLANT Manufacturers’ Outlook 2019 survey. Of those,

19% were not making any significant investments: top

reason, not necessary for continuing operations (29%).

$1.77 MILLION

All Industries

Agriculture and forestry

Minining and oil and gas extraction1

Utilities

Construction

Manufacturing

Wholesale

Retail

Transportation and warehousing

Finance and insurance

Public sector2

Others

1. Includes quarrying.2. Education, health and public administration

0.40.30.0 0.2-0.1 0.1percentage points

-0.2

Source: Statistics Canada


12 PLANT April 2019

ELECTRONICS

MICROART SERVICES MAKES

IT BIG IN PCB ASSEMBLYSmaller customers, smaller volumes and connectivity are driving growth.

BY KIM LAUDRUM

I t may surprise some to learn that there’s a booming elec-tronic component manufac-

turing industry right here in Canada.

While many have sub-con-tracted such work overseas, it turns out there are 530 or so small- to medium-sized firms contributing to a $1.9 billion domestic industry.

They specialize in printed circuit board (PCB)design and assembly, among other things. And they are doing well. Really well.

Mark Wood, CEO of Microart Services Inc., says that when he started with the company 15 or so years ago, it was doing $3 million or $4 million a year in sales. “We’re 10 times that. We’ll do $40 million this year.”

The Markham, Ont.-based company, which employs 279 people at its 42,000 square foot plant, has experienced 16% an-nual growth compounded over the past 10 years, according to Wood. “Solid,” he emphasizes.

In fact the company has also made the Canadian Business list of Canada’s fastest growing companies at number 85 among manufacturers and 485 overall.

What’s driving Microart’s

growth? “Most circuit board assembly companies chase large volumes. But we’re good at servicing small customers and small volumes,” he points out. “We try to treat all customers the same, whether they need 50 or 500 boards. We attract a lot of start ups and as they grow, we grow with them.”

Bernie Lewe founded Mi-croart in 1981 as a printed circuit board design house only. “This was back in the days before computers when design was done by hand using coloured crayons, then co-loured tape,” Wood explains. Once computers came along, circuit board design was getting easier so the company got into assembly.

Fifteen years ago, Lewe sold the company to father and son team Peter and Tyler Fisher. Wood was brought in to run it and Lewe stayed on. Wood, a graduate of George Brown College who had worked in printed circuit board design and assembly, became the manager. In 2018, Peter and Tyler sold the firm to Wood. Lewe is still there three days a week.

(L-R) Overlooking the warehouse, SMT and through-hole areas of the plant.Printed circuit boards waiting for through-hole process.Operator loading hand-placed through-hole components.

MADE IN

CANADA



Microart has nine surface mount lines (three are high-speed SMT lines) and three X-ray machines at the Markham location. Wood says they have no problem making capital equipment investments because of the pace of growth.

Now manufacturers seek Mi-croart to help them implement sensors and chips on hardware products ranging from commu-nications satellites to paintball guns. “Sensor manufacturers are doing a booming business,” Wood says.

Building unique boardsConnectivity is a big factor. “Data is driving the growth,” Wood says. Microart’s business in medical devices connected to the Internet of Things (IoT), for example, is “expanding dramat-ically.”

Think monitors for weight loss, the heart, blood pressure and blood glucose levels for diabetics. When connected, these devices collect data, offer analysis, help pinpoint problems and provide alerts to patients and their healthcare workers.

“There doesn’t seem to be any part of the body they don’t mon-itor now,” Wood says, adding most of the market is for home sensors to help keep the costs of hospitalization down.

Connectivity is creating residual business on a monthly basis for those who are manu-facturing products with a data stream. “It’s really accelerating. The product is a means to an end. Now you can stay in touch with the customer. Hardware is like software. They know more about your business than they did before,” Wood says.

For example, heavy equip-ment manufacturers offer their customers preventive mainte-nance by connecting machinery to indicate when bearings are

Mark Wood inspecting SMT components currently loaded on feeders that are being placed by the pick and place machine. PHOTOS: RODNEY DAW


14 PLANT April 2019

about to wear out. Such a ser-vice could save customers time, equipment wear and money.

Because of this the supply chain has improved, Wood says. “The supplier already knows that you are out of something before you do.”

Microart expanded its oper-ations a year ago, openning a new plant in Buffalo, NY. Eight people work one shift on two surface mounting lines, and there are plans to hire “probably 12 more,” Wood says. “The new plant hasn’t gone the way we expected. It has attracted Cana-dian businesses seeking to meet ‘Build in USA’ requirements.”

Microart is the only company Wood knows of that offers an apprenticeship training pro-gram for printed circuit board assembly. In-house trainers are certified IPC. “We also train some customers,” he says.

Building unique boardsIn any given month, Microart will serve 300 different customers. The firm is now building 1,000 to 1,100 unique boards. Using ERP software from Nivision Dynamics, a share point system helps them track the status of the boards as they proceed through assembly in the shop.

“We can allow our customers in through a portal so they can see the status of their job,” Wood says. “We buy all components, put them into a kit. It could be one bin or many depending on the job. Once the backend work is complete, including the design program and stencil, the boards are loaded onto SMT feeders through the paste process. An automated optical inspection verifies we’ve done it correctly.”

Any solder joints that can’t be visibly inspected are x-rayed. An automated wave solder machine or low volume hand solder might be used on some selected solder mechanisms. Once that’s done, the product is tested then shipped to the customer, or it’s assembled into the customer’s product.

Although Microart ships to some 50 countries, 90% to 95% of the jobs are delivered within

North America.David Olive has known Wood

for 30 years. Olive is a partner in Netonix LLC, which designs, manufactures and distributes equipment worldwide for the WISP (wireless internet service provider) industry in New Hol-land, Pa.

“Mark introduced us to a company that wanted to manu-facture something he knew we could help them with. We didn’t

have the volume to go to China,” Olive says. “You have to have someone on the ground if you’re dealing with China. If you’re a Tier One customer in China you might be okay, otherwise you need to be there to monitor things. Microart is good in that they can jump to your needs and do a good job. And the Canadian dollar helps.”

Barry Papoff is COO of Markham, Ont.-based Arcx. The

firm provides plant operators with an error-proofing system for assembly lines. Key to this system is the logic controller, connected to the Industrial Internet of Things (IIoT). It col-lects metrics, such as cycle time or errors. It also offers an inter-face for training the operator in each basic step of the process. Microart assembles the device.

Why does Arcx have its engi-neered product manufactured in Canada rather than, say China?

“Labour rates are rising in China,” Papoff says. “They’ve risen five times since I’ve been dealing with manufacturers in Beijing. It’s getting harder to find low-cost geographies.” Also, start-up product costs at a dis-tance “create quite the barrier. Design to prototype to manu-facture can be done at a much faster rate here.”

He appreciates Microart’s flexibility.

“There has been a renaissance of hardware and electronics manufacturing within Ontar-io,” Papoff notes. “We have an ecosystem fed by a number of large electronic global compa-nies. Research in Motion (now Blackberry Ltd.), for example, sprinkled the ecosystem with all these bright people. We have an-gel investors and good technolo-gy incubators. That seeds things and creates start ups. Microart is a small, local company with a good reputation. Mark has a finger on the pulse of the local community and business needs,” he says.

Ultimately, Papoff wants to support the local community “because this is where Mark’s children and my children are going to grow up and look for jobs.”

Some of those opportunities will surely be in the growing Canadian electronic component manufacturing industry.

Kim Laudrum is a Toron-to-based business writer and regular contributor to PLANT. E-mail [email protected].

Comments? E-mail [email protected].

(Top-bottom) Partial assembled PCBs waiting for manual hand assembly.Operator cleaning assembled board after selective soldering.Fully assembled boards being tested.





PRESSURE POINT

Skills Ontario offers the province three recommendations for improving engagement.

BY JOE TERRETT, EDITOR

F illing skills gaps continues to be a challenge for manufac-turers. The PLANT Manu-

facturers’ Outlook 2019 survey shows it to be one of the greatest challenges for 46% of manufac-turers, third on a list behind costs and pressures on pricing.

Canadian Manufacturers & Exporters’ management issues survey found 69% of respon-dents are facing immediate skills shortages, while 75% ex-pect to face shortages over the next five years. There are two key reasons: rapidly changing technology is changing skills needs; and there are not enough young people choosing careers in manufacturing-related fields.

Ontario, Canada’s manufactur-ing heartland, will face a short-age of 190,000 workers in 2020, and 560,000 by 2030, according to research by the Conference Board of Canada.

The Excellence in Manufac-turing Consortium (EMC) has been tracking skill vacancies with its ManufacturingGPS online resource, which provides benchmarking tools for human resources, labour, skills and capabilities needs (http://man-ufacturingGPS.ca). The Owen Sound, Ont. non-profit that helps manufacturers become more competitive identifies the positions most in demand as: production/machine operators; welders; maintenance and trade; sales, business development; and development engineers and quality.

First the good news: EMC sees a big jump in technology invest-ment (8.3% between 2017 and 2018) as a reason for spending on training.

But over the past two years there has been a worrying shift

around what are the major re-cruitment challenges for hard to fill vacancies, with the low num-ber of applicants moving from third position to number one.

“Employers need to take another look at how they’re recruiting and consider non-tra-ditional ways,” says Jean-Pierre Giroux, EMC’s national director, skills and talent development.

Some non-traditional strat-egies include foreign-trained workers and training unem-ployed people, but manufactur-ers are also being encouraged to look at how they bring people into the sector.

“A lot of companies still have HR practices that belong in the 1970s and 1980s,” Giroux says.

Companies need to change the way they operate. For exam-ple, manufacturing is typically viewed as full-time work, but he says many millennials don’t nec-essarily want to work 40 hours a week. They’d rather do 20 to 30

hours, so manufacturers need to look at how they can accom-modate them, and eventually convert them to full time.

A bigger roleSkills Ontario, the not-for-profit and registered charity focused on bringing more young people into skilled trades, wants to build on the work it has been doing for the past 30 years and alleviate some of the challenges sectors such as manufacturing are expe-riencing. Now it has an opportu-nity to do so in a significant way as the Ontario government under Premier Doug Ford moves to wind down the Ontario College of Trades. The OCoT is the reg-ulatory body established under previous Liberal governments to govern skilled trades. The Ford government intends to develop a replacement model that reduces regulatory burdens for business-es, in line with its Making Ontario Open for Business Act.

This presents an opportuni-ty for Skills Ontario to play a bigger role. It has built an expan-sive network of stakeholders in the apprenticeship system that includes businesses, educational institutions at all levels, unions, students, apprentices and tradespeople. It runs programs and skills competitions, pro-vides resources and it aims to do more, but needs additional resources to do so.

The organization has out-lined how it can help build the momentum in the promotion of skilled trades careers in a Jan. 29 presentation to the govern-ment’s Standing Committee on Finance and Economic Affairs, and it has included recommen-dations for improving engage-ment among stakeholders, especially students looking at career choices.

“There are a lot of good things going, but they’re not tied to-gether,” says Ian Howcroft, CEO of the Waterloo, Ont.-based orga-nization. “We see Skills Ontario tying them together.”

He sees the province’s move to an apprenticeship ratio of 1:1 as a positive. “It will make it easier and provide more opportuni-ties for smaller employers to hire an apprentice and make it easier for an apprentice to find a placement.”

But the presentation notes some of the issues that need attention in the current model, such as the ongoing stigma at-

Filling the skills

GAPINCREASE ENGAGEMENT AND BUILD MOMENTUM

Training on a CNC machine. PHOTO: ADOBE STOCK


http://manufacturingGPS.ca

16 PLANT April 2019

tached to trades and technology careers, as well as the ineffi-ciencies and complexities of the system.

“In some ways it’s archaic and cumbersome with no clear path for many students. Even if you want to pursue an apprentice-ship, it’s hard to find your way through,” Howcroft says.

Skills Ontario believes the governance/regulatory elements should be separate from the promotion and awareness of ap-

prenticeships and skilled trades, allowing for greater flexibility and effectiveness.

Its first recommendation is for the Ontario government to scale up successful programming. Skills Ontario notes 91% of its audience (students and appren-tices age 10 to 29) were likely to pursue a career in the skilled trades or technologies – yet the organization was only able to reach a small fraction of that group with its current resources.

Expand outreachSkills Ontario delivers presenta-tions to approximately 120,000 Ontario youth, which represents about 10% of the student popu-lation between grades 7 and 12. The submission notes there’s a significant opportunity to expand this outreach and engagement, including reaching younger students as well as influencers such as parents, teachers and guidance counsellors.

Recommendation two calls

for engaging non-traditional or under-represented groups in skilled trades, such as young women, indigenous groups and new Ontarians.

For example, Skills Ontario piloted a program for Indigenous youth in 2011, which comple-mented its Liaison Program and involved the hiring of three full time Indigenous staff members. They have been building rela-tionships in schools and commu-nities, while tailoring programs and activities to serve them.

There’s also significant de-mand for programming aimed at female elementary students. The Elementary Young Women’s Conference provides events and programs aimed at young wom-en in grades 7 to 12. But this and other events at the Skills Ontar-io Competition have significant wait lists.

Recommendation three calls for single-window access for apprentices. Stakeholders find it difficult to access good quality information and the apprentice-ship system. The organization suggests it would be an appro-priate conduit for such an ap-proach on the promotional side.

Howcroft described Skills Ontario as a potential hub for the many organizations operat-ing in the skills space to better co-ordinate what’s going on across the province and ensure the limited resources everyone has are used to best advantage. “Given our strengths, history, staff, network and volunteers, we’re well-placed to work with the government to achieve some of its goals and objectives with regard to modernizing appren-ticeships and building a better skills system in Ontario.”

The challenges manufactur-ers face finding people with the right skills to fill vacancies lends some urgency to the Ford government’s plans to rejig the province’s skills model. Cutting the regulatory burden is smart but its new plan should also look at how stakeholders can work more effectively.


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PERFORMANCE

Explain linkages when teaching a process.

BY HUGH ALLEY

A healthcare practitioner observing another prac-titioner noticed he made

some key decisions without ask-ing the family members about the patient. “How can he make good decisions when he doesn’t have that critical information?” she asked.

It was clear that he didn’t see his job as including efforts to collect information. In his silo, the job was to make the deci-sion.

The same problem often oc-curs in manufacturing. We ask employees to make decisions, but they struggle. Either they don’t have needed information (not their job because someone said they don’t want the opera-tor speaking to the customer) or they lack guidance about how to weigh the information they have. In both scenarios, the result is a decision that is less than ideal.

One company removed two weeks from its build cycle after sales started collecting all the information engineering needed when the order was taken. Sales people didn’t like the extra work, but when they noticed there were fewer follow-up ques-tions, a better buying experience for customers and faster deliv-ery, they were willing to do it.

Even better, products weren’t stalled while the production crew waited for clarification.

Unrecognized silo focusThe silo problem is particularly acute for products that must be configured or engineered, but it shows up even in simple operations. For example, in

metal forming, if the customer’s desired radius isn’t known, the operator doesn’t know which profile to use in the press. This delays either the design process or the production process.

Most people are unaware of their silo focus. Fortunately, when they do become aware, they’re willing to improve the

overall process by adding a small amount to their work. For example, sales may not be interested in production details. But salespeople at one company were willing to take on some additional data entry once they understood it would reduce the error rate and the delivery time of their orders. In their market, that was a competitive advan-tage.

The take away? When you are explaining a new process or teaching an employee new to a process, be sure to explain the linkages. How does this step of the process affect the later stages? How do others depend on the work being demonstrated or taught?

When staff members have this understanding, they’ll work more effectively, and less likely to take short cuts with the inevi-table side effects.

Hugh Alley is an industrial en-gineer based in the Vancouver area who helps organizations achieve significant perfor-mance gains. Call (604) 866-1502 or e-mail [email protected].


Make better DECISIONSLIBERATE INFORMATION FROM JOB SILOS

Information silos lead to less than ideal decisions. PHOTO: ADOBE STOCK




http://www.bucan.com

18 PLANT April 2019

FINANCE

Some of the key measures with pros and cons from key industry associations.

BY PLANT STAFF

T he Trudeau government’s 2019 pre-election budget is big on spending and some

measures will help Canadian manufacturers. There are pro-visions for skills and training, innovation, regulatory reform and business measures, among others.

The Canada Training Credit is for people 25 to 65 and is applied to tuition, training costs and related fees. The annual $250 credit goes into a national account and accumulates to a lifetime maximum of $5,000. There’s also an Employment Insurance training support ben-efit. It provides up to four weeks paid leave every four years (55% of average weekly earnings) to help cover living expenses when it’s necessary to leave work for additional training.

There are innovation mea-sures of interest. Several programs are related to the forestry sector involving up to $251 million over three years, starting in 2020-21. There’s also $100 million over four years going to the Strategic Innova-tion Fund starting in 2019-20, which will promote innovation through collaboration between academia, not-for-profits and the private sector.

Additional funding of $38 million will be provided over five years for Futurpreneur Canada, aimed at young entrepreneurs.

And $100 million over three years aims to stimulate econom-ic growth in Western Canada, provide incentives for innova-tion and attract investment.

Shawn Casemore, president of the Excellence in Manufacturing Consortium (EMC), a non-prof-it that helps manufacturers become more competitive, is pleased to see the government investing in human capital. “More specifically we welcome the significant investment that is

being made in work-integrated learning – preparing students for the workforce – which is much needed in the Canadian manu-facturing sector.”

Canadian Manufacturers & Exporters (CME) is encouraged to see a commitment to increas-ing funding for skills training. “One quarter of a billion dollars and creating 40,000 new work integrated learning spots is certainly welcome and will help address chronic labour challeng-es,” said Dennis Darby, CME’s president and CEO. “However, manufacturers continue to be concerned about the overall competitiveness of the industry as no significant changes to business taxes or other mea-sures to help business invest-ment were announced.”

The national association is encouraged the government is upholding the Accelerat-ed Capital Cost Allowance and export supports, and it’s pleased to see investment in more reliable internet service to rural areas, elimination of the income threshold for accessing the enhanced credit under SR&ED, and continued

support for regulatory reform. “But these measures will not be sufficient to stimulate the level of investment that is required in the industry and the Canadian economy more generally,” he said in a statement.

No tax reviewA TD Economics report noted lit-tle in the budget to address inter-national competitiveness issues. “There was again no mention of a longer-term tax system review (both corporate and personal) to address how the economic reality has changed since the Carter Commission’s report more than 40 years ago,” said chief economist Beata Caranci and senior economist Brian DePratto in their report.

The Canadian Federation of Independent Business (CFIB) said the new Canada Training Benefit and the EI Training Support Benefit raise concerns about the role of employers – both in ensuring the training is relevant to the world of work and in administering the time away from the workplace.

CFIB acknowledged the small business premium rebate for

businesses that pays $20,000 or less per year in EI premiums. Starting in 2020, a rebate will aim to reduce premiums, but details are pending.

The business association that represents small enterprises has been pushing for a reduction in red tape, and some prog-ress is evident in the budget. It notes investment in improving government services to help businesses comply with and un-derstand their tax requirements; a permanent dedicated line for tax service providers; and wait time improvements for business inquiries to the Immigration Refugees Citizenship Canada phone line.

But the CFIB noted some missed opportunities:• Measures to offset the costs

of the Canada Pension Plan increases nationally and the new federal carbon tax affect-ing small businesses in several provinces.

• Exempting previous passive investments from the small business tax changes to maintain access to the small business tax rate.

• Expanding the red tape reduction one-for-one rule to include policies, guidelines and legislation.

• Keeping today’s debts from becoming tomorrow’s taxes by creating a plan to balance the budget within the next three to five years.The CFIB intends to keep

these issues top of mind as the election time approaches.


Budget BUSINESSWHAT’S IN IT FOR CANADIAN MANUFACTURERS

Some measures in Budget 2019 benefit industry. PHOTO: ADOBE STOCK




LOGISTICS

Ten tips for managing its impact on your supply chain.

BY MARCO ROMANO

Extreme weather is becom-ing increasingly common. Floods, hurricanes and

wildfires have devastated vast regions around the world with increased frequency. This winter, much of Canada and the Midwestern United States expe-rienced unprecedented extreme cold.

These events put severe stress on local authorities and infra-structures. Government offices, schools and airports often close as roads and railways become impassable.

In the manufacturing world with its expansive supply chains, a weather crisis in the Midwest can affect a small business owner in rural Ontar-io. Manufacturing has become more integrated than ever before, and while weather crises are difficult to predict and man-age, it is possible to prepare in advance to mitigate the impact.

Here are 10 tips to help maxi-mize capacity, procure reason-able rates, and ship securely when bad weather strikes:

1. Don’t try to time the market. Conduct a regular

procurement exercise every year at the same time to review rates and service providers. Doing it on a consistent schedule per-mits better alignment between shipper and provider networks, helping to develop long-term, sustained pricing levels regard-less of major weather events.

2. Maintain a stable set of service providers. Measure

how much freight your carriers are actually hauling, compared to what they promised. If you give too much freight to non-in-cumbents, higher rates will result in both emergency and non-emergency situations.

3. Investigate what drives ongoing fluctuations in

the market. Truckload capaci-ty, like the economy, is cyclical:

market changes affect available capacity. Watch certain eco-nomic indicators to understand what’s happening in the market and anticipate potential impacts on transportation rates. That can leave you better prepared to respond to rate changes during extreme weather, such as hurri-canes.

4. Understand how re-lationships between

shippers and receivers can significantly influence car-rier engagement. Don’t leave carriers to deal with problems that fall outside their regular duties: shippers are ultimately responsible for resolving any issues carriers encounter with receivers, including those that are weather-related. Negative carrier treatment can reflect poorly on your business.

5. Ensure your transporta-tion providers are adapt-

able. Can they step in and move additional freight volumes in a pinch? Do they have the size and scale to help you easily find solu-tions to unexpected problems that may arise during floods

and fires? Consider business processes and the attributes of freight (lead time, dwell time) to see if you can optimize with appropriate capacity commu-nities. This will help mitigate volatility and make the market more predictable.

6. Look for any missing links between inbound and

outbound strategies. You may have access to providers who can deliver inbound raw materi-als to supplement your outbound transportation needs, especially useful during times of limited resources.

7. Be flexible. Rigid appoint-ments prevent efficient

transit times and good use of drivers’ hours of service. Some-times, driver delays can last a day or more because a receiver has a small dock and too small a timeframe for unloading. Stay flexible whenever possible to minimize frustration in crisis scenarios.

8. Communicate within your organization. Avoid service

failures and unmet expectations by educating your company

(especially salespeople) about how weather affects capacity. Explain your plan for situations that could significantly curtail capacity, such as blizzards: will you ship early to avoid the rush? Will you leave inventory in strategic locations, balancing maintenance costs against po-tentially higher transportation rates?

9. Connect with your carri-ers’ local offices. No one

can better inform you about specific local situations than people on the ground. When choosing a carrier, ask questions about procedures during harsh weather: Will it be possible (and easy) to reach a local represen-tative during an emergency? Will they quickly understand your situation and resolve it in real time?

10. Use the technology at your disposal. When you

choose a carrier, pay specific attention to the technological tools it has to offer. Real time visibility helps you manage cli-ent expectations and maintain good business relationships. Moreover, technological tools also help you redesign your logistics strategy in real time to respond to severe weather, which will promote efficiency and result in lower costs.

No one is insulated from the market pressures and cycles that drive supply and demand. But you can manage those fac-tors to create the best possible experience in any marketplace. Better preparation and clear communication will reduce the risk to your logistics supply chain.

Marco Romano is director of transportation sales at C.H. Robinson, a provider of pro-vider of multimodal transpor-tation services and third-party logistics in Vaughan, Ont. Visit www.chrobinson.ca/en-ca.

Comment? E-mail [email protected].

Extreme WEATHERAVOID ITS EFFECT

ON TRANSPORTATION

Weather crises can disrupt a manufactur-er’s supply chain. PHOTO: ADOBE STOCK


http://www.chrobinson.ca/en-ca


20 PLANT April 2019

CCOHS SAFETY TIPS

Create a written policy that provides a protocol for reporting incidents.

M aia is dreading Monday morning and a supervisor who makes a habit of

intimidating and humiliating her in front of co-workers. This and other types of harassment play out for many workers and is an issue that often goes unreport-ed. The harm this causes affects employees, clients, customers and visitors.

Everyone is entitled to pro-tection while on the job. When workplace harassment and vio-lence are not defined they can go unnoticed and unreported.

There’s a tendency to think of violence as physical – hitting, shoving, kicking and other threatening behaviours. But it can also be arguments, prop-erty damage, vandalism, theft, psychological trauma and an-ger-related incidents. There are also less obvious, but equally destructive, behaviours such as verbal or written threats, rumours, pranks and abuse such as swearing, insults or conde-scending language.

According to the Canadian Ini-tiative on Workplace Violence, one in five violent incidents (in-cluding physical assault, sexual assault and robbery) occur in the workplace. But violence is not limited to traditional work-places. It can happen offsite at work functions such as confer-ences, training, tradeshows, social events, in clients’ homes or away from work (such as a threatening phone call at home).

A 2014 Queen’s University poll found 23% of Canadians have experienced workplace harass-ment. It’s a form of discrimina-tion that involves any unwanted physical or verbal behaviour that offends or humiliates. Generally, it persists over time but includes serious one-time incidents.

Harassment occurs when someone makes unwelcome remarks or jokes based on race, national or ethnic origin,

colour, religion, age, sex, sexual orientation, marital status, family status or disability. Repeated and persistent actions aimed at an in-dividual can torment, undermine, frustrate or provoke a reaction. With persistence, this behaviour pressures, frightens, intimidates or incapacitates the victim.

Decreased productivitySexual harassment is any conduct, comment, gesture or contact of a sexual nature likely to cause offence or humiliation, or that might, on reasonable grounds, be perceived as placing a condition of a sexual nature on employment, or any opportunity for training or promotion.

A 2014 survey on sexual harassment in Canada by Angus Reid revealed three in 10 Canadians said they had been sexually harassed at work, but very few of them reported this to employers. The top reason for not reporting was a preference to deal with the incident them-selves. Other reasons included embarrassment, not sure it was harassment, fear it would hurt their career, and the feeling

that the issue was too minor. Three-quarters of respondents described the issue as import-ant and that it should get more attention. The same number also believed it’s widespread or at least a common occurrence.

The human and financial costs of workplace harassment and violence are great. Victims can be affected physically and psy-chologically. Common responses range from low morale and pro-ductivity, changes in eating and sleeping patterns, denial, panic

and anxiety, depression, fear, post-traumatic stress disorder, and thoughts of suicide.

Companies also experience increased absenteeism and healthcare costs, as well as legal expenses when steps aren’t taken to prevent harassment and violence.

Managers must not tolerate any violent behaviour includ-ing aggression, harassment or threats of violence. Such behaviours create a psychologi-cally unsafe work environment where employees are fearful and anxious.

Commitment from manage-ment is best communicated in a written policy that includes a protocol for employees to report incidents.

Learning to recognize work-place violence and harassment is an important first step toward prevention.

The Canadian Centre for Occupational Health and Safety (CCOHS) in Hamil-ton contributed this article. CCOHS provides information, training, education, manage-ment systems and solutions that support health and safety programs and the prevention of injury and illness in the work-place. Visit www.ccohs.ca.


ProtectEMPLOYEES…FROM WORKPLACE VIOLENCE AND HARASSMENT

Heated arguments can be classified as violence. PHOTO: ADOBE STOCK

Employee protectionMost Canadian jurisdictions have a “general duty provision” in their OH&S legislation that requires employers to take all reasonable precautions to protect the health and safety of employees. More information on this topic is available in the OSH Answers (www.ccohs.ca/oshanswers) fact sheet OH&S Legislation – Due Diligence.

Canadian jurisdictions that have specific workplace violence prevention regulations include Alberta, BC, Saskatchewan, Manitoba, Ontario, Nova Scotia, Newfoundland and Labrador and PEI. Canadian federally regulated workplaces (that fall under the Canada Labour Code, Part II) also have specific regulations. Quebec has legislation regarding “psychological harassment,” which may include forms of workplace violence.

Many jurisdictions have working alone regulations, which may have some implications for workplace violence prevention. Ontario also has specific harassment legislation.


http://www.ccohs.ca


http://www.ccohs.ca/oshanswers


SHOW TIME

Discover how millennials, cannabis, diversity and demographics are changing the workplace.

Safety is a priority for manufacturers. Manage-ment is facing a number of

evolving conditions that impact the workplace, including the legalization of cannabis, mental health, diversity and changing demographics of the workforce. These issues and others will be addressed at Partners in Pre-vention 2019, running April 30 to May 1 in Mississauga, Ont.

The health and safety confer-ence and trade show presented by Workplace Safety & Preven-tion Services (WSPS) will focus on safety superheroes who advocate for health and safety practices in the workplace. The two-day event includes three keynote speakers, 60 sessions, workshops and professional development courses, and more than 400 exhibitors booths on the trade show floor showcasing the latest innovations, market trends, products and services.

This year’s keynote speakers include Canadian comedian, TV personality, political satirist and author Rick Mercer; Scott Strat-ten, a social media influencer on Forbes.com, who will discuss how today’s business climate is changing at an unprecedented rate; and Mark Henick, whose TEDx talk, “Why We Choose Suicide,” had more than 5 mil-lion views, will look at mental health.

Sessions cover a range of is-sues including: cannabis, mental health, inclusivity and diversity, and the rise of the millennial worker in the workplace. Here are some highlights: • Canadian cannabis 101. Jay

Rosenthal, co-founder and president of Business of Can-nabis, will explain how Cana-da and the US are regulating cannabis; the promise of medicinal cannabis; and what the future has in store for Can-ada as a world leader in the cannabis industry. He’ll also

touch on the impact cannabis may have on workplaces.

• Cannabis – six months in. A panel will review the progres-sion leading up to legalization and early information on the development of the impair-ment standard by CSA.

• Millennial management – maximizing tenure and leveraging their potential. Generation workplace expert Jeff Butler will expose the mindset of one of the larg-est demographics and show how to turn a career hopping millennial into a devoted employee by tapping his/her potential and creating a strong management structure.

• Up the ante on workplace mental health/wellness. Adam Palmer, safety and prevention supervisor, Niagara Casinos, and Amanda Silliker, editor, Canadian Occupational

Safety, will discuss how man-aging employee mental health and overall wellness reduces costs, improves safety and sustains happier employees.

• Fatigue management: Cheaper than therapy. Mike Harnett, president of Solaris Fatigue Management, deliv-ers the most recent scientific research on the best way to optimize personal health, safety and performance while minimizing the consequences of fatigue.

• Smartphones and the pur-suit of workplace wellness. Human resources consultant Jim Lees examines the impact smartphone technology has had on the workforce and con-siders the challenges balanc-ing the increasing demands for productivity and efficiency with the mental health and wellness of employees.

• Harassment in the work-place: How to identify, prevent and take action against it in the #Me-Too era. Lauren Bernardi, Bernardi Human Resources Law LLP, will lay out the legal definitions of harassment, the importance of bystander interventions and other pre-ventative measures, and raise awareness of sexual harass-ment and how to address it.Partners in Prevention will be

held at the International Centre in Mississauga, Ont. Register at PartnersinPreventionConfer-ence.com.

WSPS, based in Mississau-ga, Ont., represents more than 167,000 member firms across the agricultural, industrial/manu-facturing and service sectors.


Celebrate safety SUPERHEROSPIP 2019 COVERS PRESSING SAFETY ISSUES

More than 400 exhibitors booths at PIP 2019 (last year’s trade show floor pictured). PHOTO: WSPS



PLANT

MANUFACTURING TABLETOP EXHIBIT

2 0 1 9PlantExpo is an effective forum for face-to-face interaction between buyers and sellers

A series of one-day tabletop shows highlighting leading-edge manufacturing technologies for the Canadian market

MARK YOUR CALENDAR!

To discuss exhibit options please contact:

www.plantexpo.ca

April 23, 2019Mississauga Convention Centre Mississauga, ON

May 15, 2019TRADEXAbbotsford, BC

June 19, 2019Sherbrooke ExhibitionCentreSherbrooke, QC

The list of attendees includes manufacturing decision makers in these areas:

• C-suite executives • Maintenance and engineering

• Purchasing • Plant operations • Plant and design engineering • Logistics/Transportation/Distribution

• Research and Development • Transportation

FREE ADMISSION FOR ATTENDEES!

PROGRESS BEGINS HERE

Ilana FawcettNational Account Manager416 829 [email protected]

PLANT


DEX, PLANT Expo and MMP co-locate to bring together more technology AND more attendees at one convenient venue.BRINGING TOGETHER MORE TECHNOLOGY UNDER ONE ROOF

*

*The Mississauga event only co-locates with DEX.

PLT Expo March2019_FP house ad_AMS.indd 1 2019-03-26 9:25 AMPLT_April 2019_AMS.indd 22 2019-04-04 2:57 PM

http://www.plantexpo.ca



How the sport parallels manufacturing and leadership.

BY RICHARD KUNST

I was introduced to white water kayaking at an early age. As I became involved in the

competitive side of the sport a couple of different types of chal-lenge emerged: the downriver race where you had to accom-plish the shortest time from the start to the finish; or the slalom event, where you had to navigate the course through a series of (typically) 20 gates.

Downriver racing is like doing mass production where skill is minimal but you rely heavily on strength and the state of your equipment – the lightest boat and a strong paddle. In slalom, you need skill and the ability to read water currents to accom-plish the best overall lapsed time – like doing a mixed-model or small lot production.

Both types of race require a lot of practice to create the muscle memory needed to ne-gotiate the course. But practice is not enough. You need a coach who looks at your style and offers tips to improve technique, eliminate time wasters and to mentally challenge you to dig down and excel. These coaches are our team leads, supervisors and managers.

As I approached my first com-petitive race, I asked the coach what I should do at the starting gate. His answer was simple: as the starter holds the back of your kayak and begins the countdown, reach inside to pro-duce the strongest paddle stroke followed by an even stronger paddle stroke. As the count ends and your race begins with your ultimately strongest paddle stroke, you keep that pace until the race is completed.

In today’s manufacturing en-vironment, we give our best and sustain this energy during our daily engagements. We’re aware of the environment but rely on muscle memory to accomplish

tasks that we learned during practice.

What else did I learn during those formative years?

Start strong or you’ll be dis-couraged right from the start, which will only amplify during the race.

Slalom events consist of sever-al mini races. While navigating through a series of gates you gain penalties for missing or touching one. If you view the race one gate at a time, blowing one sequence will not discour-age you for the entire race. This makes me a believer in hourly run boards (that tracks targets and compares them to produc-tion over a shift).

In slalom, you concentrate on the orientation of the kayak and ensure you never touch a pole. Weight to boat volume is

a huge KPI if you intend to win and as you approach a gate, you focus on submerging your boat to sneak under it. This is like single minute exchange of dies (SMED), which is converting as many changeover steps to external (while the machine is running), and to simplify and streamline the remaining steps.

New edgeOne of the most important lessons learned stems from the coach who was not big on giving compliments or acknowledging our capabilities. I was not the strongest or most capable pad-dler on our team, but I did have a need to be acknowledged and perhaps complimented, but it never happened.

Because I was so frustrated with my coach, I took a week

away from work to concentrate on my paddling. I focused on improving my elapsed time, worked hard on skill and tech-nique, and over several days I improved significantly. How could he not be impressed with this accomplishment?

During our team practice day, I paddled my sequence knowing it was a personal best. I glided up next to the coach looking for that compliment or acknowl-edgement of a sequence well done. His response, “You didn’t fall in.”

“What?” I exclaimed. “The purpose is not to fall into the water.”

The coach said he could see that I had improved but since I didn’t fall into the water, I didn’t have a new edge.

So I learned the real purpose of practice: it’s okay to fail.

Richard Kunst is president and CEO of Cambridge, Ont.-based Kunst Solutions Corp., which helps companies become more agile, develop evolutionary management and implement lean solutions. Visit www.kunstsolutions.com. E-mail [email protected].


PLANT


2 0 1 9PlantExpo is an effective forum for face-to-face interaction between buyers and sellers

A series of one-day tabletop shows highlighting leading-edge manufacturing technologies for the Canadian market

MARK YOUR CALENDAR!

To discuss exhibit options please contact:

www.plantexpo.ca

April 23, 2019Mississauga Convention Centre Mississauga, ON

May 15, 2019TRADEXAbbotsford, BC

June 19, 2019Sherbrooke ExhibitionCentreSherbrooke, QC

The list of attendees includes manufacturing decision makers in these areas:

• C-suite executives • Maintenance and engineering

• Purchasing • Plant operations • Plant and design engineering • Logistics/Transportation/Distribution

• Research and Development • Transportation

FREE ADMISSION FOR ATTENDEES!

PROGRESS BEGINS HERE

Ilana FawcettNational Account Manager416 829 [email protected]

PLANT


DEX, PLANT Expo and MMP co-locate to bring together more technology AND more attendees at one convenient venue.BRINGING TOGETHER MORE TECHNOLOGY UNDER ONE ROOF

*

*The Mississauga event only co-locates with DEX.

PLT Expo March2019_FP house ad_AMS.indd 1 2019-03-26 9:25 AM

THINK LEAN

Riding the white

WATERKAYAKING AND LEADERSHIP LESSONS LEARNED

Downriver racing is like mass production. PHOTO: SUPASTE


http://www.kunstsolutions.com


24 PLANT April 2019

CASE HISTORY

Successful performance improvement initiatives drive cost savings.

BY STEVE GAHBAUER

F or any progressive plant, the goal is always to perform maintenance more efficiently

and aim for world-class reli-ability. It takes effort, but it’s achievable, as illustrated by a global medical and pharmaceuti-cal device company.

The case study was presented by Jason Ballentine, the gen-eral manager of engineering operations at ARMS Reliability, a global consulting firm based in Austin, Tex. It specializes in helping industry derive more benefits from their assets, avoid unplanned downtime, and reduce operating costs. Ballentine presented the study at the MainTrain maintenance, reliability and asset manage-ment conference, convened in Ottawa by the Plant Engineering and Maintenance Association of Canada (PEMAC).

He said the successive im-provement initiative at one of the unidentified manufacturer’s facilities, was based on choos-ing a machine or line performing below desired levels and using reliability-centred maintenance (RCM) to improve maintenance strategies. This approach involv-ing a single machine at a single facility saved $150 million over 10 years as operations and main-tenance personnel united to

improve efficiency and reliabili-ty. They reduced downtime, idle time and labour reallocations.

There were challenges, of course. An important, intricate machine was frequently down, causing decreased production, increasing emergency and corrective labour costs. ARMS Reliability was charged with completing a study to risk-opti-mize the maintenance strategies for 40 asset types. The company gathered a cross-functional

team of more than 20 experts consisting of maintenance, reli-ability and operations members, plus personnel from other sites.

Bonus benefitsARMS Reliability began by gath-ering failure and maintenance information for the machine from a variety of sources, including key site personnel, machine operations and maintenance documentation, site drawings and the SAP ERP system. It also held a series of in-person, onsite facilitation sessions to collect re-maining data. Once all gathered information was validated, ARMS modelled various maintenance scenarios comparing different strategies, spares and holding options, and generated budget predictions over a 10-year period.

The models, completed using the RCMCost module of Iso-graph’s Availability WorkBench, simulated three scenarios: run to failure (RTF); current main-tenance practices, showing the effectiveness of the company’s existing planned maintenance

strategy for the machine; and optimized maintenance, demon-strating what would happen with optimal tasks performed at optimal frequencies.

A “bonus” benefit of the study was how the team-based ap-proach brought together mainte-nance and reliability personnel, plus site operations, directors and management, to discuss issues. With the involvement of operations professionals, the process became a platform for communication, new awareness and understanding between these groups. It helped propel the company toward a world-class reliability program via plant-wide buy-in.

The cost comparison showed optimized maintenance has potential for huge cost savings by redirecting the workforce toward tasks that are valuable to the company, and away from wasted efforts; by stocking low-cost, long-lead-time spares to dramatically decrease machine downtime; and by training operators wherever recurring incidents delay start-ups and produce machine trips.

Ballentine said the recom-mended solution consisted of two simple steps: catch belt failures just before they happen by turning monthly inspections into a daily task; and eliminate the wait time for spares by al-ways stocking extra belts.

ARMS Reliability’s RCM study provided the medical device company with a quantified new maintenance strategy expected to save 91% in costs over the cur-rent strategy in the next 10 years in a single facility. It showed per-formance initiatives work.

Steve Gahbauer is an engineer, a Toronto-based business writ-er and a regular contributing editor. E-mail [email protected].


Get more from your

ASSETSHOW RCM HELPED

A MEDICAL DEVICE COMPANY

RCM improves maintenance strategies. PHOTO: ADOBE STOCK

RCM in seven stepsReliability-centred maintenance (RCM) is a process used to ensure systems continue to do what’s required under the present operating context. It’s defined by the technical standard SAE JA1011, Evaluation Criteria for RCM Pro-cesses that sets out the minimum criteria a process should meet in this order: 1. What is the item supposed to do and its associated performance standards?2. In what ways can it fail to provide the required functions?3. What are the events that cause each failure?4. What happens when each failure occurs?5. In what way does each failure matter?6. What systematic task can be performed proactively to prevent, or to

diminish to a satisfactory degree, the consequences of the failure?7. What must be done if a suitable preventive task can’t be found?Source: Wikipedia





INSIDE MAINTENANCE

Increasing inspection frequency has a huge impact on the bottom line.

BY STEVE GAHBAUER

E lectrical systems play a critical role in a manufactur-er’s ability to be competitive

and profitable. They have to be properly maintained. Unplanned outages cost millions of dol-lars and have a direct negative impact on the performance of plant engineers, operators and managers. Although often poor-ly understood by stakeholders, electrical system reliability is directly tied to productivity and operating costs. Quantifying the statistical probability of an electrical system failure opens the door to prioritizing critical system components and mini-mizing maintenance costs.

It’s not surprising then that how we look at the maintenance of electrical power systems and equipment is evolving. This is being driven by several influ-ences – cost, technology and an enhanced human resource base. Efforts are directed to exploring new approaches to monitoring, diagnosis, life assessment and condition evaluation of critical plant infrastructure.

Power interruptions and electrical equipment failures are one of the major symptoms of ageing electrical distribution

components. Consequently, many manufacturers are migrat-ing from traditional time-based maintenance to condition-based reliability maintenance.

One of the monitoring technol-ogies is electrical maintenance surveillance. Surveillance and inspection systems determine the condition of individual

assets and include – but are not limited to – infrared thermogra-phy, airborne ultrasound, motor current analysis, partial dis-charge testing, corona cameras and visual inspections.

Arc flash dangerMaking the transition from reactive maintenance to a

totally proactive structure is not an overnight project. It takes time, effort and planning, with commitment from all levels of an organization. The key is to have a reliable means to evaluate the condition of equipment compo-nents and the system as a whole.

These aspects of electrical systems maintenance have been specifically addressed in Main-Train maintenance conferences, convened by the Plant Engineer-ing and Maintenance Associa-tion of Canada (PEMAC).

Here are highlights from presentations by Rudy Wodrich and Doug Marshall (see Meet the presenters, page 26):

Wodrich says the challenge of an electrical maintenance sur-veillance system is the inspec-tion and equipment used yield their most valuable results when inspecting equipment operat-ing under full load conditions. But this is also the time when equipment is most dangerous to maintenance technicians. The surveillance equipment normally requires direct access, or direct line of sight, to the energized components inside the electrical system. This means panels have to be open, which is an extremely dangerous condi-tion. In many cases the posted arc fault currents are too high, and access is prohibited.

Every year, thousands of electrical workers in the US and Canada are injured or even killed while performing their duties. Ontario’s Ministry of Labour

Protect your electrical

SYSTEMMAKE THE MOVE TO CONDITION MONITORING

Electrical outages interrupt production and drive up costs. PHOTO: ADOBE STOCK

TECH TIPS

Grounding VFDsHow to avoid problems

Maintenance crews frequently run into troubles with variable

frequency drives (VFDs), including windings and bearings. There are two common issues: the drives were never tuned, or were not tuned following motor or drive repairs or replacement; and ground leads are in the same conduit as standard leads from the drive to the motor.

Follow manufacturers’ installation instructions. They contain directions

on how to tune the drive and recommen-dations for cabling and grounding. Improper grounding will cause problems with how the drive operates.

One trouble spot is loose ground leads in the conduit combined with motor cables from the drive. This causes electrical unbalance between the phases and ground leading to a transformer effect (EMI) that generates voltage and current in the

ground lead. Heating, potential fire or shock hazards occur, depending on the size of the ground lead and amount of current.

Use special inverter cables that either balance the phases to grounding circuit, shield cables ground-ed at both ends, or distance the output

cables from control and ground cables.

Source: MotorDoc LLC newsletter, How-ard Penrose. Visit www.motordoc.org.

A small VFD. PHOTO: CJ COWIE


http://www.motordoc.org

26 PLANT April 2019

DESIGN & MANUFACTURING INNOVATIONS BEGIN AT ADM TORONTOFOR TODAY’S DESIGN ENGINEERING PROJECTS

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• 3D Printing

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• CAD/CAM Software

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reports over a 10-year period 28 workers were killed and 255 seriously burned from arc flash incidents. According to the Bu-reau of Labor Statistics in the US, there are more than 300 fatalities each year from electrocution with an arc flash component, making this the fourth leading cause of occupational fatality. These numbers are nearly half of what they were 20 years ago, which is a marked improvement, for several reasons. First, person-nel have a better understanding of risks due to training. Second, arc flash labelling requirements on equipment provide infor-mation to front-line personnel regarding the kind of personal protective equipment (PPE) they should use. Finally, there have been significant improvements in the types and quality of PPE.

Unfortunately, the average number of annual arc flash occurrences has not fallen at the same rate over that period. In

fact, there are still 4,000 non-dis-abling electrical contact injuries each year and 3,600 disabling electrical contact injuries, and non-age-related or random fail-ures account for nearly 90% of equipment failures.

The value of condition-based maintenance (CBM) is avoiding costs related to material and la-bour to perform repairs, as well as downtime and lost productiv-ity. Material lead-time may be substantial, depending on what has failed and the severity of the failure. A 2 MVA liquid-filled pad-mount transformer, for instance, could easily have 12 to 16 weeks lead-time. If that transformer was the linkage to a renewable power generation asset, such as a solar inverter or wind turbine, the downtime in lost energy harvest would be between $40,000 and $55,000, which is more than the cost of the transformer itself.

Harmonics risk Several technologies are used to measure the condition of elec-trical equipment. They include ultrasonic testing, motor current analysis and power quality spot monitoring.

Harmonics pose the greatest risk of potential premature equipment failure. Non-linear loads that draw current for only a portion of the voltage wave-form cause harmonic current. This includes variable-speed drives, DC rectifiers, UPS systems and lighting ballasts. In addition, harmonic currents can be magnified by poorly de-signed power factor corrections through a phenomenon called resonance. The issue with har-monic currents is a significantly higher heating in current-carry-ing components of the distri-bution network, proportional to the square of their harmonic order.

Imaging devices, a non-con-tact method, also measure con-dition. They keep the user away from danger and don’t intrude upon, or affect, the target’s operation.

Corona cameras work in the UV spectrum and detect coronal

ionization around a conductor or insulator.

Thermal imaging cameras provide extremely accurate quantitative results. Accurate temperature readings are im-pacted by various factors, such as the distance to the target, reflectivity of the surface, ge-ometry, humidity of the air and transmission rate of an infrared viewing window. Modern IR cameras adjust for most of these factors and an experienced technician can secure very accu-rate results. NETA publishes guidelines for maximum tem-

peratures in different types of electrical equipment compared to actual measurements.

Safety concerns for electri-cians and other maintenance personnel are front and centre. Appropriate controls eliminate hazards, reduce risk by design, and apply safeguards. The final type of electrical maintenance safety devices is online moni-toring. It includes permanently installed versions of power qual-ity and partial discharge (PD) monitoring. PQ monitoring, with permanently installed hardware and sensitive software, detects

FRAMEWORK

Managing your assetsIt’s about more than reliability

GMAM document takes maintenance performance to a higher level.

There will always be a need for the maintenance and repair of in-

frastructure. Now plants are under pressure to get things done, deliver value and meet goals.

To help make this happen, the Global Forum on Maintenance and Asset Management (GFMAM) – of which Plant Engineering and Maintenance Association of Canada (PEMAC) is a supporting and con-tributing partner – has issued a document titled, The Maintenance Framework.

The details of this release are outlined in an Asset Management Solutions newsletter, published by Len Middleton (www.asset-man-agement-solutions.com). Here’s a quick outline: • The five principles are value,

efficiency and effectiveness, in-tegrity, execution, and leadership,

providing decision criteria to drive behaviours, decisions, and actions that support ex-cellence in maintenance. The subject groups are business requirements, maintenance strategy management, maintenance management, maintenance execution, deliverables, continual improvement, and allocation

of resources. • Three of the asset manage-

ment landscape subjects are: operations and maintenance decision-making; maintenance delivery; and reliability engineer-ing. These subjects are part of what would be considered part of maintenance management and reliability, therefore a subset of asset management.Both business requirements and

maintenance strategy management will get inputs from the asset man-agement landscape of the Strategy and Planning subject group.

Looked at it this way, asset management is more broadly busi-ness-focused at the organizational level, and maintenance management is more tactically focused on main-taining the function of the assets.

The Maintenance Framework helps explain the various symbiotic relationships that take maintenance performance to a higher level. Get a copy at http://gfmam.org.

Maintenance on a metal lathe. PHOTO: ADOBE STOCK

MEET THE PRESENTERS

Rudy Wodrich is the leader of product development at IRISS

Inc. in Bradenton, Fla., a company that provides asset tracking for the electrical industry. He’s an electrical engineer whose career has revolved around designing electrical distribution systems for industrial, commercial and power generation applications. He holds an MBA from the University of To-ronto and works on critical asset surveillance technologies.

Doug Marshall is a se-nior project engineer at Magna IV Engineering-

with locations in Western Canada and offices in the US, a company in the field of high voltage power, automation and controls, and that commissions electrical power sys-tems for industry. Marshall has 35 years of experience in electronics and electrical power distribution. He currently conducts feasibility and power system studies and holds degrees from Concordia and McGill universities in Montreal.


http://www.asset-management-solutions.com

http://gfmam.org

DESIGN & MANUFACTURING INNOVATIONS BEGIN AT ADM TORONTOFOR TODAY’S DESIGN ENGINEERING PROJECTS

Attend Design & Manufacturing Canada to discover the industry’s latest innovations, processes, and materials to run your business more efficiently and cost effectively.

• 3D Printing

• Rapid Prototyping

• CAD/CAM Software

• Outsourced Design and Manufacturing Services

• Materials and Coatings

admtoronto.com/mro

JUNE 4-6, 2019 // TORONTO, ONTARIO TORONTO CONGRESS CENTRE

Use promo code MRO for free expo registration

PLT_April_ADM.indd 1 2019-03-21 11:16 AMPLT_April 2019_AMS.indd 27 2019-04-04 2:57 PM

http://admtoronto.com/mro

28 PLANT April 2019

transients that often come down from the utility and have an impact on sensitive equipment. Without PQ monitoring in place, it’s often impossible to prove the utility was the cause of damage or production outage. PD moni-toring is permanently installed monitoring of the ultrasound signature of equipment and is primarily used in HV utility substation applications.

Keep personnel safeWodrich emphasized the need for electrical maintenance safety device technologies to be part of a CBM program to ensure personnel are kept as safe as pos-sible. The hierarchy of control concept encourages employing a “safety by design” approach as the next best protocol in instances where it’s not possible to perform the necessary work with the equipment de-energized. Permanently installed online monitoring technologies provide significant additional value to de-

termine when it may be prudent to conduct in-depth inspection and proactive maintenance.

“They can be even more valu-able when they tell us nothing is wrong and allow us to use our limited maintenance man-hours on more productive tasks than pure calendar-based mainte-nance activities,” Wodrich said.

In his presentation about evaluating the reliability of electrical distribution systems in a plant, Doug Marshall stated a study could be conducted. This reduces unplanned outages (production loss), as well as maintenance costs and spare parts inventory, while increas-ing equipment performance, extending equipment life, reduc-ing safety risks and providing financial benefits.

There is a specific process to this. It’s called value stream mapping, which is a lean man-agement method for analyzing the current and future state of a manufacturing process that

details the series of events. It takes a product or service from beginning to the customer. For an electrical system that’s run-ning a complex manufacturing process, it’s a way to identify the critical processes (motors/pumps, boilers, crushers, filters, process machinery) in the value chain and a means to prioritize where reliability improvements are to be made.

There are several RCA tech-niques that can be employed, depending on the complexity of the electrical distribution system. The best-suited are fault tree diagram and failure mode and effects analysis.

Marshall said that an electri-cal reliability study identifies improvements to reduce single points of failure, identifies aged components that require replacement, reduces loading in electrical equipment, reduces insulation stresses in electrical equipment, improves preventive maintenance planning, installs

predictive maintenance technol-ogies, and reduces MTTR with critical spares inventory and contingency planning.

He concluded his presentation by emphasizing it’s of para-mount importance that reliabili-ty be one of the cornerstones of electrical distribution design at the outset, along with meeting code and safety requirements. However, once an optimal design is implemented, factors such as ageing components, changing operating conditions and maintenance procedures can affect the system’s reliabil-ity. So it’s recommended an electrical reliability analysis be conducted at regular intervals.

Steve Gahbauer is an engineer, a Toronto-based business writ-er and a regular contributing editor. E-mail [email protected].


COME VISIT US AT BOOTH #811 AND #621

MAY 5 & 6

PLT_April_SEWEurodrive.indd 1 2019-03-21 2:15 PM





TECHCENTRE

Pick-and-place robots will handle 25% of manufacturing goods by 2000. PHOTO: IFS

SUPPLY LINES

ELECTRIFYING 25 YEARSITC Electrical Components is cel-ebrating 25 years of supplying the industrial market with electrical and automation components.

The distributor, based in Con-cord, Ont., offers more than 10,000 parts from its Toronto warehouse. It plans special deals for custom-ers through 2019.

PARTNERSHIP EXPANDEDEndress+Hauser Canada Ltd. and Westburne have extended the scope of their partnership agree-ment to include Manitoba.

Last year Westburne, an electrical distributor in Burlington, Ont., became an Endress+Hauser channel partner for Ontario and Saskatchewan. Endress+Hauser provides measurement instrumen-tation, services and solutions for industrial process engineering.

The three-province sales channel leverages the strategic alliance between Rockwell Auto-mation and Burlington, Ont.-based Endress+Hauser, which was established to address today’s process manufacturing challeng-es and develop next-generation control systems.

A RELIABLE ACQUISITIONFicodis Group is acquiring Reliable Bearing, a company specializing in power transmission products based in Mississauga, Ont.

That’s 14 acquisitions for Fico-dis, a Montreal-based industrial distribution group.

It’s expanding by establishing partnerships with major distrib-utors throughout Quebec and Ontario.

Reliable Bearing, a Canadi-an-owned company founded 35 years ago, has 25 employees.

Combined with its acquisition of Transbearco last September, Ficodis is continuing to expand its network, with power transmission points of sale in Levis, Que., Otta-wa, Montreal and Toronto.

Voice-driven solutions, pick-and-place robots will lead.

BY ANTONY BOURNE

A new generation of artificial intelligence (AI) solutions will prove themselves in

2019. They’ll build trust, urgency and understanding of what AI actually is, and just how much it can deliver. Voice-driven solutions will lead the charge while pick-and-place robots in smart warehouses will deliver a competitive edge as companies advance their use of robotic pro-cess automation. Here are three

predictions for manufacturing:Prediction 1. Fifty per cent of

all manufacturers will be using AI in some form by the end of 2021. The implementation of AI will change industry, business, processes and companies, but for many businesses, targeted solutions are already here! This year will be all about AI spread-ing with targeted, project-based solutions hitting the ground running.

The term ‘AI’ misleads many manufacturers, suggesting a large end-to-end system. In real-ity, it’s a collection of technolo-gies, including natural language processing, vision identification, chatbots, analytics and automa-

tion, each with its own strengths and applications. What they all share is intelligence: a high de-gree of accuracy and the ability to learn from mistakes – fast.

You can’t implement AI any more than you can implement the internet. Before you initiate any project, figure out what the business goal and target will be. What do you want to improve and enhance? The more target-ed your objectives, the more competitive and transformative the results.

Smart solutionsPrediction 2. Twenty-five per cent of manufacturing planners will be talking to their systems by the end of 2020.

AI solutions are smarter and more eloquent than most of us realize. A customer survey found two thirds of those who said they had never used AI actually had, through chatbots. Quality was so high, the chatbots were indistinguishable from human speech. The same survey found 84% of respondents were com-fortable using voice-activated AI at home, in the form of Alexa, Siri or Home. If simplicity, speed

AI’s 2019 FORECASTTHREE PREDICTIONS

FOR MANUFACTURING

INDUSTRY 4.0


30 PLANT April 2019

Innovative ideas for plantsLEADING EDGE

PREPARE FOR CYBERSECURITY

Free tools from Dragos identify ICS assetsManufacturers of all sizes should take cybersecurity risk seriously.

PLANT Magazine’s Manufacturers’ Outlook 2019 study shows 74% of companies rate their level of concern over risks to security as medium to high; and 42% have experienced breaches.

Industrial threat and response specialist Dragos Inc. has introduced free assessment tools to help qualified companies secure their industrial controls systems (ICS).

The company, based in Hanover, Md., recently acquired NexDefense, a provider of ICS visibility technology. As part of this deal, Dragos has intro-duced Dragos Community Tools to help manufacturers identify assets with interconnected communications that are potentially unknown to these companies.

The tools include NexDefense’s Integrity (continu-ous, passive ICS network monitoring with basic DPI and asset fingerprinting capabilities); and Cyberlens, an assessment tool developed by Dragos that helps the community quickly process packet captures and visualize ICS environments.

Dragos contends visibility is the prerequisite for the development and deployment of cybersecurity architectures to detect and respond to threats. That leads to the Dragos Platform, a continuous passive monitoring software that identifies and visualizes assets, detects threats and provides playbooks for quick responses to attacks.dragos.com

Detect and respond threats. PHOTO: ADOBE STOCK

MORE EFFICIENT ENERGY MANAGEMENT

Real-time tech covers asset and facilitiesTraditionally, building automation and facility manage-ment have been independent of each other resulting in significant operational inefficiencies. But there’s a growing need to meet environmental and regulatory compliance.

Kontrol Energy Corp. is extending its IoT technology solutions into the global asset and facilities management space to turn those inefficiencies around.

The Vaughan, Ont.-based energy efficiency special-ist employs IoT, Cloud and SaaS technology to deliver end-to-end facilities management with real-time building data management, centralized asset performance, fault detection, predictive analytics and corrective workflow.

Benefits include streamlined manufacturing process-es, workforce efficiency, longer asset life, enhanced energy savings, operating cost reductions and labour optimization.www.kontrolenergy.com

IoT, Cloud and SaaS technology applied. PHOTO: ADOBE STOCK

and accuracy are crucial consumer benefits, imagine what they could do on a manufacturing line.

BMW’s smart integration of Alexa into its models in March 2018 was widely applauded. The integrated voice activation went way beyond skin deep, adding layers of service and performance capability to the driving experience. Voice-activated solutions are also being used in auto-motive production.

In Japan, NEC is using voice-ac-tivated solutions for order picking, where line personnel simply give spoken instructions and orders are created instantly.

Prediction 3. Pick-and-place robots will put away 25% of manufac-tured goods by the end of 2020.

Amazon’s smart warehouses have raised the performance and savings bar. Robots don’t need lighting or heating, so energy costs plummet. There are no time or weight limits on breaks, shifts or loads. And the flexi-bility, fluency, reach and economy of picking and placing mean no wasted time or effort. Utilization of space is also better. A 24-hour, black box warehouse will store and do more, without having to get bigger.

As it is with AI so it is with robots: small, targeted use cases that will continue to grow. For example, a North American company extended its use of robotics from loading boxes to complete material handling. Full lights-out warehouses may be some years away, but this advance has be-gun with some companies beginning work with automated facilities.

This year will see these predicted technologies gain traction as they become more targeted and proj-ect-driven. Achieving small, concrete improvements will lead to bigger change, reaching new heights.

Antony Bourne is the UK-based glob-al industry director for manufac-turing for IFS, a global enterprise software vendor with Ontario offices in Waterloo, Toronto and Ottawa. E-mail www.linkedin.com/in/ant-onybourne/. Visit www.ifsworld.com/ca.



http://www.kontrolenergy.com

http://www.linkedin.com/in/antonybourne/

http://www.ifsworld.com/ca


http://dragos.com


Three-stage approach. PHOTO: ADOBE STOCK

PANIC BUTTON FOR LONE WORKERS

Emergency Alerts app for ZelloWorksWorkers in manufacturing or other heavy industrial settings using ZelloWorks who operate solo or are deskless can now add a panic button feature to the app.

Zello Inc., provider of the push-to-talk “walkie talkie” voice messaging app widely used by consumers, is expand-ing its presence in the industrial space with Emergency Alerts.

ZelloWork users in crisis situations simply press a button to send (with high priority) a location and an audio recording to a designated emergency channel. Doing so immediately shares the nature and details of the emergency to all appro-priate parties who can then respond accordingly.

Once the initiator of the emergency is no longer in dis-tress, the alert is dismissed. Everything that occurs on the app during an emergency is recorded, providing a valuable record of the event that transpired.

Add-on cost is $2 per user, per month.zello.com/try

TRACK AND MANAGE INVENTORY

Real-time using barcode softwareA new application from Dynamic Systems Inc. pro-vides manufacturers with real-time inventory counts using barcodes to manage inventory and upload the information to any accounting system.

Its Advanced Checkmate Mobile application records inventory from receiving through storage and shipping and has a feature to count inventory and print a discrepancy report. The Redmond, Wash.-based software developer specializing in traceability and inventory systems says this provides the speed and accuracy of using barcode software without the cost of implementing a full warehouse system.

The application resides on a mobile device. Middle-ware stores inventory totals, receipts, and shipping information and uploads the appropriate data to an ERP or accounting system.www.Dynamic-SystemsInc.com

For solo workers. PHOTO: ADOBE STOCK

Detect and respond threats. PHOTO: ADOBE STOCK

PEOPLE BEFORE ROBOTS

Putting RPA in the hands of usersRobotic Process Automation (RPA) is becoming increasingly important as a way to accelerate digitization and improve productivity while reducing costs and errors.

Softomotive, a UK-based provider of RPA solutions, has de-veloped what it describes as a new way to deploy: it’s people before robots by putting RPA in the hands of the users.

The People1st Approach has three stages: innovate to em-power the many and accelerate performance collaboratively; incubate to filter and nurture the best output from the innova-tion phase; and implement to scale what is proven to work.

Each phase breaks down into different steps to provide a seven-stage blueprint for adoption.

Softmotive cites advantages as: lower upfront costs; lower risk; more RPA opportunities; more innovation; its flexible; and it engages more people.

Lear more at www.softomotive.com/People-1st-Approach.

Eliminates the cost of full warehouse system. PHOTO: ADOBE STOCK


http://www.Dynamic-SystemsInc.com

http://www.softomotive.com/People-1st-Approach

http://zello.com/try

32 PLANT April 2019

PUMPS

NEXT STEP IN LIQUID RING TECHWet, humid and dirty pump applications? Atlas Copco’s LRP 700-1000 VSD+ intelligent liquid

ring vacu-um pumps will handle them.

The compact, high per-formance and energy

efficient variable speed drive pumps with HMI control are enclosed in a strong, noise-con-taining canopy the protects against dust and water. Oper-ating noise is in the 65 dB(a) range.

Inlet, outlet and mains cable points are positioned on the top of the pump for plug-and-play installation.

The twin VSD system op-erates in harmony within the pump. The primary VSD accurately maintains required vacuum levels by controlling the operating speed, matching performance to process demand while saving energy. The second VSD regulates water circulation in response to the operating conditions.

Intelligence features include

automatic seizure prevention, ASP, automatic cavitation pre-vention and ACP.

Atlas Copco in Canada, based in Mississauga, Ont., provides compressed air and vacuum equipment, industrial power tools, construction equipment, service and maintenance.www.atlascopco.com/en-ca

MONITORING

AC TRANSFORMERS CHECK STATUS

Measure primary current with AcuAMP Solid Core current transformers from Automation-Direct.

Two different window open-ings and two mounting styles along with numerous secondary ratios meet most applications.

The compact AC transformers in primary current ranges up to 1,000 A check motor run status, indicate pump dry run and monitor conveyors, heaters and power.

Secondary current is 5 A with multiple connection options for input devices that are com-patible with standard power monitors, data loggers and panel meters.

Apertures of 1.56- and 2.5-in. diameter are available.

AutomationDirect is a distrib-utor of industrial automation products based in Cumming, Ga.www.automationdirect.com

SYSTEM DETECTS FAULTS, PART AND TOOL VARIATIONS The artificial intelligence capability of the Brankamp X7 in-process monitoring system from Marposs optimizes machine efficiency, improves part quality and limits unplanned downtime and tooling costs.

The system for cold and hot forming, thread rolling and stamping operations detects manufacturing faults as well as part or tool variations.

Setup is streamlined and rework reduced to increased capacity for additional orders without having to invest in addi-tional presses.

The X7 system is operated from a 15-in. touchscreen with 30 channels capable of monitor-ing maxi-mum forces, envelope curves and trend pro-gressions, as well as run times, setup times and downtime; or sensitive process areas such as distorted parts or a missed feed.

Depending upon the applica-tion, sensors are placed either on the machine, in the tooling or in the dies, connecting the press to an X7 unit. Users see at a glance if their machines are running, if their OEE is where it needs to be and what is happen-ing at the machine.

FactoryNet 4.0 capability passes machine information directly to other stakeholders by means of intelligent online

communication. The operator filters the information, preset-ting it individually as desired so that each employee receives only relevant data. Displayed onscreen, the operator gets a real-time overview of produc-tion status.

Marposs is a provider of measurement and process mon-itoring technologies based in Auburn Hills, Mich.www.marposs.com

SYSTEM GUARDS CLEANROOM The Sentinel system from Sensaphone ensures temperature, airflow, humidity and airborne par-ticulates do not compro-mise products in facilities that require a controlled environment or designated cleanroom.

The system uses cloud tech-nology to provide supervised 24/7 remote monitoring of up to 12 different environmental and equipment status condi-tions. When the system detects a sensor reading has moved out of the preset range, it sends no-tification via phone call, text or e-mail to designated personnel for action.

Operators access real-time data from anywhere using any mobile device to check status information, change settings, disable alarms and readjust temperature limits right from the Sensaphone app.

If the communication link is interrupted, the system gen-erates an alert indicating the internet connection is lost or there is a cellular communica-tions problem.

Enhanced data logging func-tionality allows users to print, graph or export accurate histori-cal records.

Sensaphone is an Aston, Pa. provider of remote monitoring products.www.sensaphone.com

COMPRESSED AIR

SAFELY CLEAR SMALL DIAMETERSEXAIR’s Soft Grip Back Blow Safety Air Gun uses the smallest nozzle available to blow debris and liquids from inside small pipe or hose diameters, channels, bores, holes, internal threads and other internal part features.

An array of holes on the Model 1004SS M4 provides a forceful back-facing 360-degree airflow to clear out coolant, chips and light oils from machining processes. The type 316 stainless steel nozzle prevents blowing chips farther into a part, tube or pipe and eliminates any safety hazard created by blowing

debris out the far end of a pipe or tube. Air consumption is only 4.5 scfm at

80 psig with a low sound level of 75 dBA. The nozzle is manufactured to clean inside openings as small as ¼ in. (6 mm) and up to 1 in. (25 mm).

EXAIR Corp. is a manufacturer of compressed air-operated products based in Cincinnati.www.exair.com

PRODUCTS AND EQUIPMENT

Smallest nozzle.

Low noise operation.

Two mounting styles.

Eliminates unplanned downtime.

Provides real-time data.


http://www.atlascopco.com/en-ca

http://www.automationdirect.com

http://www.marposs.com

http://www.sensaphone.com

http://www.exair.com


EVENTS

Partners in Prevention 2019 Health & Safety Conference & Trade ShowWSPSApril 30 – May 1, Mississauga, Ont.Focus is on the ‘safety super heroes’ who advocate for health and safety in their workplaces. More than 60 edu-cational sessions examining legislative and legal issues, leadership, human resources, hazards, mental health and workplace culture. Visit www.partnersinpreventionconference.com.

PLANT Expo 2019Annex Business Media, FMA Inc.May 15, Abbotsford, BCJune 19, Sherbrooke, Que.Products and solutions for manufacturing, processing machinery and MRO markets. Co-located with Design Engineering’s DEX Expo and Canadian Metalworking’s MMP Expo. Visit www.plantexpo.ca.

CNAM 13th Annual ConferenceCanadian Network of Asset ManagersMay 6-9, Kelowna, BCExplore asset management challenges through leading edge professional development, idea sharing, workshops and networking with peers and new players in government, academia and industry.

Visit http://cnam.ca/upcoming-/2019-conference.

Operational Excellence in Energy, Chemicals and Resources Summit IQPC/PEMACJune 4-6, CalgaryFor oil and gas, chemicals and resources companies to help them eliminate sources of risk, cost and complexity in their operations. Focus is on optimizing safety, efficien-cy, sustainability and reliability. Presented by IQPC and the Plant Engineering and Maintenance Association of Canada (PEMAC). Visit https://opexsummit.iqpc.com.

Plast-ExUBM June 4-6, TorontoFor Canada’s plastics processing marketplace. Showcas-es products and innovative business solutions covering marketing, packaging services, material handling and logistics. Visit http://admtoronto.com/plastex.

Pack Expo Las VegasPMMISept. 23-25, Las Vegas Presented by the Association for Packaging and Process-ing Technologies. Co-located with Healthcare Packaging EXPO. Visit www.packexpolasvegas.com.

PLANTWARE

Advanced encryption. PHOTO: ADOBE STOCK

PARTNERSHIP ENHANCES INDUSTRIAL CYBERSECURITYSchneider Electric has entered into a global partnership with Vericlave, a cybersecurity tech-nology firm in Dallas.

The provider of energy management and automation technology (with Canadian offices in Mississauga, Ont.) will provide Vericlave’s advanced encryption technology to secure and protect customers’ critical IT and OT systems from cyberattack.

Vericlave will help companies bolster their networks from within. Its technology combines with Schneider Electric’s Eco-Structure, its open, interoperable, IoT-enabled system architecture and platform.

The Dallas company’s intru-sion-prevention system overlays a zero-trust stealth model at the network perimeter and within existing infrastructure. This provides a secure communica-tion tunnel between sites and to extend layers of defence across an enterprise.

The solution shrinks the attack surface by more than 90% (when compared to traditional internet protocol virtual private network solutions) to eliminate the risk of incidents that lead to plant shutdowns.

And Schneider Electric says its plug-and-play capability reduces installation, maintenance and other ownership and operating costs by 50% or more.

The technology also allows industrial enterprises to extend their current infrastructure so dis-parate sites become extensions of the operations centre.www.vericlave.com

MOTION CONTROL

SYSTEM BUNDLES MOTION TASKS

Bosch Rexroth’s MLC motion control system handles up to 192 synchronized axes. Adding the new XM42 embedded control tops off the motion kit.

The system software includes numerous pre-defined technolo-gy functions that only need to be parameterized. The wizard-sup-ported generic application tem-plate (GAT) speeds up commis-sioning of simple applications and coordinated hardware. Users create synchronized axis motions within a matter of

minutes that GAT automatically converts into PLC code.

For more complex applica-tions, numerous pre-defined functions, such as winding and register control, belt synchro-nization and various different robotic kinematics, simplify fast engineering. Users select the corresponding software pack-age to synchronize up to 64, 128 or 192 axes.

Bosch Rexroth, a global supplier of drive and control technologies, has Canadian headquarters in Burlington, Ont.www.boschrexroth.ca

ELECTRONICS

SIC DIODES UP PERFORMANCELittelfuse Inc. added to its line of 650 V, AEC-Q101-qualified silicon carbide (SiC) Schottky Diodes.

The two diodes offer advan-tages over traditional sili-con-based devices, including negligible reverse recovery cur-rent, high surge capability and

a maximum operating junction temperature of 175 degrees C.

The LSIC2SD065DxxA diode has current ratings of 6, 10, or 16 A in a TO-263-2L package. Current ratings for the LSIC2S-D065ExxCCA are 12, 16, 20, or 40 A in a TO-247-3L package.

The diodes dissipate less en-ergy and operate at higher junc-tion temperatures than alterna-tive solutions. They also require smaller heat sinks and support a smaller system footprint.

Littelfuse is a global manufac-turer of circuit protection, pow-er control and sensing products based in Chicago. Littelfuse.com

Fast commissioning.

Smaller system footprint.


http://www.boschrexroth.ca

http://www.partnersinpreventionconference.com

http://www.plantexpo.ca

http://cnam.ca/upcoming-/2019-conference

https://opexsummit.iqpc.com

http://admtoronto.com/plastex

http://www.packexpolasvegas.com

http://www.vericlave.com

http://littelfuse.com

34 PLANT April 2019

POSTSCRIPT

BY JAYSON MYERS

R ob Wildeboer will tell you there’s no shortage of companies with great technologies looking to partner with manufacturers. The executive

chairman of Martinrea, one of Canada’s leading auto parts companies, often meets entrepreneurs with a prototype or working model who tell him they’ve done 95% of the work in developing a tech-nology and are wondering whether it might be of interest to his company. His response? He now has at least 95% of the work yet to do to ensure it can be used in manufacturing.

Clearly technological capabilities are changing rapidly. Digital and other advanced technolo-gies are revolutionizing manufacturing, whether it’s products, production processes, operating systems, customer and supplier interactions or business models. Canada has leading research capabilities and a wealth of start-ups developing new technology applications. We also have strong manufacturing capabilities and companies that will need to adopt new technologies to remain competitive and grow. So, what’s the issue?

New technologies are capable of doing some amazing things, but manufacturers need solutions for their customers and their own operations that are effective from a technical point of view. They must also be cost competitive, manageable and improve quality and performance. It’s difficult to develop a technology to a stage where it can be produced or applied in full-scale production.

Because production problems are complex, it’s not good enough to plug in a new device or piece of software and expect it to do the trick without thinking about a whole range of requirements necessary for the effective deployment of that technology. Digital technologies are disrupting production, materials handling, supply chains and business processes because they need a sys-tems-based approach to be managed effectively.

In any case, manufacturers are looking for inte-grated solutions, not one-offs. When it comes to advanced manufacturing, technology companies rarely have all the pieces of the puzzle.

There’s another side to the problem. Manufactur-ers often find it difficult to identify the opportuni-ties for improvement that advanced technologies offer, and what the optimal solution might be. It’s even more difficult to work out what the busi-ness requirements are for successful technology deployment. The capabilities of Canada’s research, technology and skills training community are not widely known. Integrating solutions is a big job, es-pecially for smaller companies that make up more than 90% of the manufacturing sector. And there’s the money. Any return on investment calculation

assumes that companies have sufficient working capital to make the investment in the first place. That’s no small hill to climb.

Statistics Canada reports close to 40% of manu-facturers who invested in advanced technologies over the past three years failed to achieve their business objectives. We’ve all seen robots sitting idle at the end of an assembly line, 3D printers that aren’t being used much, or other pieces of equip-ment that aren’t running at full capacity. It’s sel-dom a problem with the technology, but more likely not fully understanding what processes need to be improved, not implementing the right technologies for the desired business objectives, not having the right skill sets to run the technology effectively, or simply the belief that throwing money at a prob-lem is going to fix it. It’s not. In any case, this is a management issue.

Canada’s Advanced Manufacturing Supercluster aims to accelerate the adoption and scale-up of new technologies in manufacturing. So bridging the divide between technology and manufacturing is a burning issue for the team at NGen Canada, and we’ve learned a few things.

First, the challenges manufacturers face when successfully managing digital technologies are to a large extent the same, regardless of sector, size or location. Second, it’s about business strategy, management capabilities and skills, which is really about people.

A third thing is the amount of translation needed to communicate customer requirements to tech providers and technology capabilities to manufac-turers. De-mystifying technology and starting from best practices in manufacturing management go a long way.

We’ve also learned how important it is to build connections and collaboration, and how difficult that is to achieve. Partnerships are important, but they demand a level of openness and trust many Canadian companies are not used to.

Collaboration makes a huge difference for busi-ness success in advanced manufacturing. NGen is funding collaborative projects with real potential to transform manufacturing capabilities across Cana-da. We’re looking for technology and manufacturing companies that want to partner. Membership is free – just tell us how you can make a difference for manufacturing in Canada at www.ngen.ca.

Jayson Myers, the CEO of Next Generation Manu-facturing Canada, is an award-winning busi-ness economist and advisor to private and public sector leaders. E-mail [email protected]. Visit www.ngmcanada.com.


Bridge the technology divide

IT’S DIFFICULT TO DEVELOP A TECHNOLOGY TO A STAGE WHERE IT CAN BE PRODUCED OR APPLIED IN FULL-SCALE PRODUCTION…

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Starting at $299.00A unique safety controller that’s modular, expandable and confi gurable for managing all safety functions of a single machine or an entire plant. This safety controller is extremely cost-eff ective whenever two or more safety devices are required.

the #1 value in automationOrder Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2019 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

Research, price, buy at:

www.automationdirect.com/safety-controller

MODULAR SAFETY INTEGRATED CONTROLLER

By:

Advantages:• Simplifi ed wiring saves time and expense• FREE & easy-to-use programing software• Modbus and EtherNet/IP communication for status signaling• Cross fault detection built-in• External device monitoring (EDM) built-in• Expandable; up to 140 devices (124 in / 16 out)• Supports 12 different types of safety devices• Agency approvals cULus, CE, TUV

Safety Control That’s Affordable AND Easy

ModbusTCPEtherNet/IP

Watch a quick overview of the MOSAIC Safety Controller at:

www.go2adc.com/mosaic

1YEAR

Orders over $49 get FAST FREE SHIPPING Our shipping policies make it easier than ever to order direct from the U.S.!

Fast free standard shipping* is available for most orders over $49 U.S., and that includes thebrokerage fees (when using an AutomationDirect nominated broker). Using our choice ofcarrier, we can reach most Canadian destinations within 2 to 3 days. Order by 6pm ET andin-stock orders ship the same day!

*2-day free shipping does not apply to drop-ships, or orders requiring LTL transport, butthose shipments can take advantage of our negotiated super-low � at rates (based on weight) that include brokerage fees.

See Web site for details and restrictions at: www.automationdirect.com/canada

To see all products and prices, visit www.automationdirect.com

All prices shown are U.S. Dollars

1904-PLANT(Canada)-SafetyController-MAG.indd 1 3/19/2019 12:35:17 PMPLT_April_AutomationDirect.indd 1 2019-03-21 11:48 AMPLT_April 2019_AMS.indd 36 2019-04-04 2:57 PM

http://www.automationdirect.com/safety-controller

http://www.automationdirect.com

http://www.go2adc.com/mosaic

http://www.automationdirect.com/canada

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